Yamaha Kodiak 450 Lit-11626-18-35 - 972

1D9-F8199-10 LIT-11626-18-35
READ THIS MANUAL CAREFULLY!

It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM450FAT
OWNERS MANUAL
PRINTED IN USA
2004.06-4.41 CR
(E)
YAMAHA MOTOR CO., LTD.
EBU00438
LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
WARNING
ALWAYS:
use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
avoid paved surfaces-pavement may
seriously affect handling and control.
Improper ATV use can result in SEVERE INJURY or DEATH.
NEVER operate:
without proper training or instruction.
at speeds too fast for your skills or the
conditions.
on public roads-a collision can occur with
another vehicle.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
B
E E R
B
E E R
EBU00776
EBU00941
1-INTRODUCTION
Congratulations on your purchase of the Yamaha YFM450FA. It represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing
machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
ATV. This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your ATV. It also includes basic maintenance
and inspection procedures. If you have any questions regarding the operation or maintenance of
your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
G NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887
FOR MORE INFORMATION.
G THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM
EBU00801
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE-
RIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to
avoid damage to the machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
AFFIX DEALER
LABEL HERE
EBU15000
1-IMPORTANT NOTICE
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to oper-
ate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regu-
lations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU01067
YFM450FAT
OWNERS MANUAL
2004 by Yamaha Motor Corporation,
U.S.A.
1st edition, May 2004
All rights reserved. Any reprinting or
unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-18-35
EBU00014
WARNING
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
Vehicle identification number .......... 3-3
Model label ...................................... 3-3
CONTROL FUNCTIONS.................. 4-1
Main switch...................................... 4-1
1
2
3
4
Indicator and warning lights.............4-2
Fuel gauge.......................................4-4
Speedometer unit ............................4-5
Handlebar switches .........................4-7
Throttle lever ..................................4-13
Speed limiter ..................................4-14
Front brake lever............................4-15
Brake pedal and rear brake
lever .............................................4-15
Drive select lever ...........................4-16
Recoil starter..................................4-17
Fuel tank cap .................................4-18
Fuel cock........................................4-18
Starter (choke) ..............................4-20
Seat................................................4-20
Storage compartment ....................4-21
Front carrier ...................................4-22
Rear carrier ....................................4-22
Front and rear shock absorber
adjustment ...................................4-23
Auxiliary DC jack............................4-25
PRE-OPERATION CHECKS ........... 5-1
Front and rear brakes ..................... 5-2
Fuel ................................................. 5-4
Engine oil ........................................ 5-6
Final gear oil.................................... 5-6
Differential gear oil .......................... 5-6
Coolant ............................................ 5-7
Throttle lever ................................... 5-7
Fittings and fasteners...................... 5-8
Lights............................................... 5-8
Switches.......................................... 5-8
Tires ................................................ 5-8
How to measure tire pressure....... 5-10
Tire wear limit................................ 5-11
OPERATION..................................... 6-1
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Warming up..................................... 6-3
Drive select lever operation and
reverse driving............................... 6-4
Engine break-in............................... 6-7
Parking............................................ 6-8
Parking on a slope........................... 6-9
Accessories and loading ............... 6-10
RIDING YOUR ATV.......................... 7-1
Getting to know your ATV ............... 7-3
Ride with care and good
judgement...................................... 7-4
Be careful where you ride.............. 7-16
Turning your ATV.......................... 7-22
Climbing uphill ............................... 7-24
Riding downhill .............................. 7-30
Crossing a slope............................ 7-32
Crossing through shallow water .... 7-34
Riding over rough terrain............... 7-37
Sliding and skidding....................... 7-38
What to do if .................................. 7-40
What to do .................................... 7-40
5
6
7
PERIODIC MAINTENANCE AND
ADJUSTMENT.................................. 8-1
Owners manual and tool kit............ 8-1
Periodic maintenance/
lubrication...................................... 8-3
Panel removal and installation........ 8-6
Engine oil and oil filter cartridge.... 8-12
Final gear oil .................................. 8-17
Differential gear oil......................... 8-20
Cooling system.............................. 8-22
Changing the coolant .................... 8-24
Axle boots...................................... 8-27
Spark plug inspection.................... 8-28
Air filter element cleaning.............. 8-31
V-belt cooling duct check hose ..... 8-34
V-belt case drain plug.................... 8-34
Spark arrester cleaning................. 8-35
Carburetor adjustment................... 8-36
Idle speed adjustment ................... 8-37
Valve clearance adjustment .......... 8-38
Throttle lever adjustment............... 8-38
Select lever safety system
cable adjustment ......................... 8-39
Front brake pad check...................8-39
Rear brake pad check....................8-40
Inspecting the brake fluid level ......8-41
Brake fluid replacement .................8-42
Front brake lever free play.............8-43
Adjusting the rear brake lever and
brake pedal ..................................8-44
Adjusting the rear brake light
switch...........................................8-46
Cable inspection and
lubrication.....................................8-47
Lubricating the brake levers and
brake pedal ..................................8-47
Rear knuckle upper and lower
pivot lubrication............................8-48
Wheel removal ...............................8-49
Wheel installation...........................8-49
Battery............................................8-50
Battery maintenance......................8-52
Fuse replacement ..........................8-52
Replacing a headlight bulb ............8-54
Headlight beam adjustment...........8-57
8
Tail/brake light bulb
replacement ................................ 8-58
Troubleshooting ............................ 8-59
Troubleshooting charts ................. 8-61
CLEANING AND STORAGE............ 9-1
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-3
SPECIFICATIONS.......................... 10-1
NOISE REGULATION.................... 11-1
MAINTENANCE RECORD ............ 12-1
ATV LIMITED WARRANTY............ 13-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................... 14-1
9
10
11
12
13
14
1-1
EBU00464
1-LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Read and understand all of the labels on your
machine. They contain important information
for safe and proper operation of your ATV.
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
Yamaha dealer.
3
1
2
Overl oadi ng thi s ATV or carr yi ng cargo i mproperl y can change
handl i ng, stabi l i ty and braki ng perfor mance and can l ead to an
acci dent. Never exceed the maxi mum front cargo l i mi t of
: 40kg (88 lbs)
NEVER si t on the carri er. Refer to i nstructi ons i n the Owner' s
Manual .
5ND-F4877-00
WARNING
1-3
4
5
Overl oadi ng thi s ATV or carr yi ng cargo i mproperl y can change
handl i ng, stabi l i ty and braki ng perfor mance and can l ead to an
acci dent. Never exceed the maxi mum rear cargo l i mi t of
: 80kg (176 lbs)
NEVER si t on the carri er. Refer to i nstructi ons i n the Owner' s
Manual .
5ND-F4897-00
WARNING
PULLING LOAD: 4900 N ( 5 0 0 k g f )
1102 l b f
TONGUE WEIGHT: 147 N ( 1 5 k g f )
33 l b f
5ND-F151K-00
MAXIMUM

LOADING LIMIT
6
1-4
7 8
9
UNDER
WARNING
YAMAHA 4XE-F415A-00
NEVER operate this ATV if you are
under age 16.
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
Turning the ATV in 4WD-LOCK
(
DIFF. LOCK
)
takes more effort.
Operate at a slow speed and allow
extra time and distance for maneuvers
to avoid loss of control.
5ND-F1558-00
WARNING
2-1
SAFETY INFORMATION
EBU13351
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
G Read this manual and all labels carefully and follow the operating procedures described.
G Never operate an ATV without proper training or instruction. Take a Training Course. Begin-
ners should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
G Always follow the age recommendation:
A child under 16 years old should never operate an ATV with engine size greater than 90cc.
G Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
G Never carry a passenger on an ATV.
G Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park-
ing lots and streets.
G Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
2-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
G Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or
jacket, and long pants.
G Never consume alcohol or drugs before or while operating this ATV.
G Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility, operating conditions, and your experience.
G Never attempt wheelies, jumps, or other stunts.
G Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al-
ways follow the inspection and maintenance procedures and schedules described in this man-
ual.
G Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
G Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
G Never operate on excessively rough, slippery or loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
G Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
G Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
2-3
G Always follow proper procedures for climbing hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear
changes. Never go over the top of a hill at high speed.
G Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight back-
ward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
G Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of a steep hill if
possible.
G Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall-
ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual. Dismount on the
uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the
procedure described in this manual.
G Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen trees. Always follow proper procedures when op-
erating over obstacles as described in this manual.
2-4
G Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac-
ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con-
trol.
G Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
G Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.
G Always use the size and type of tires specified in this manual.
G Always maintain proper tire pressure as described in this manual.
G Never modify an ATV through improper installation or use of accessories.
G Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Com-
mission at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.
2-5
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing.
Do not refuel immediately after the en-
gine has been running and is still very
hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or in the vi-
cinity of sparks, open flames, or other
sources of ignition such as the pilot
lights of water heaters and clothes dry-
ers.
When transporting the ATV in another
vehicle, be sure it is kept upright and
that the fuel cock is in the OFF posi-
tion. Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.
2-6
WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
Always operate your ATV in an area with
adequate ventilation.
3-1
EBU00032
1-DESCRIPTION AND MACHINE IDENTIFICATION
1. Rear shock absorber assembly
spring preload adjusting ring
2. Spark arrester
3. Storage compartment
and tool kit
4. Spark plug
5. Rear brake fluid reservoir
6. Front shock absorber assembly
spring preload adjusting ring
7. Brake pedal
8. V-belt case
9. Radiator cap
10. Fuel cock
11. Air filter case
12. Fuses
13. Tail/brake light
14. Engine oil dipstick
15. Oil filter cartridge
16. Coolant reservoir
17. V-belt cooling duct check hose
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Drive select lever
22. Speedometer unit
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar switch
27. Throttle lever
28. Front brake lever
NOTE:
The machine you have purchased may differ slightly
from those shown in the figures of this manual.
3-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EBU00600
Identification number records
Record the key identification number, vehicle
identification number and model label infor-
mation in the spaces provided for assistance
when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is
stolen.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
EBU00035
Key identification number
The key identification number is stamped on
the key as shown in the following illustration.
This number can be used for ordering a new
key.
1. Key identification number
3-3
EBU00036
Vehicle identification number
The vehicle identification number is stamped
into the frame.
1. Vehicle identification number
NOTE:
The vehicle identification number is used to
identify your machine.
EBU00787
Model label
The model label is affixed to the location in the
illustration. Record the information on this la-
bel in the space provided. This information will
be needed to order spare parts from your
Yamaha dealer.
1. Model label
4-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EBU00039
1-CONTROL FUNCTIONS
WARNING
EBU09420
Main switch
Functions of the respective switch positions
are as follows:
ON:
The engine can be started only at this position
and the headlights and taillight come on when
the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
1. Main switch
4-2
EBU08020
Indicator and warning lights
1. Differential gear lock indicator light DIFF. LOCK
2. Low-range indicator light L
3. High-range indicator light H
4. Neutral indicator light N
5. Reverse indicator light R
6. Park indicator light P
7. Differential gear lock indicator
8. Coolant temperature warning light
EBU10601
Differential gear lock indicator light DIFF.
LOCK
This indicator light and the differential gear
lock indicator in the display come on when the
differential gear lock switch is set to the 4WD-
LOCK position.
NOTE:
_
When the switch is set to LOCK, the differ-
ential gear lock indicator light will flash until
the differential gear is locked.
_
EBU11220
Low-range indicator light L
This indicator light comes on when the drive
select lever is in the L position.
EBU01064
High-range indicator light H
select lever is in the H position.
DIFF.
LOCK
4-3
EBU09720
Neutral indicator light N
select lever is in the N position.
EBU12500
Reverse indicator light R
select lever is in the R position.
EBU00609
Park indicator light P
select lever is in the P (park) position.
EBU11312
Four-wheel-drive indicator /
This indicator comes on when the 2WD/
4WD switch is set to the 4WD position. The
differential gear lock indicator DIFF.LOCK in
the four-wheel-drive indicator also comes on
when the LOCK-4WD switch is set to the
4WD-LOCK position.
NOTE:
_
Due to the synchronizing mechanism in the
differential gear case, the four-wheel drive in-
dicator may not come on until the ATV starts
moving.
_
DIFF.
LOCK
4-4
EBU00860
Coolant temperature warning light
When the coolant temperature reaches a
specified level, this light comes on to warn
that the coolant temperature is too hot. If the
light comes on during operation, stop the en-
gine as soon as it is safe to do so and allow
the engine to cool down for about 10 minutes.
CAUTION:
_
G The engine may overheat if the ATV is
overloaded. If this happens, reduce
the load to specification.
G After restarting, make sure that the
light is out. Continuous use while the
light is on may cause damage to the
engine.
_
EBU00052
Fuel gauge
The fuel gauge indicates the amount of fuel in
the fuel tank. When the needle reaches the
red line, refill the tank at the first opportunity.
1. Fuel gauge 2. Red line
NOTE:
_
If the machine runs out of fuel, move the fuel
cock lever to the RES position. Approxi-
mately 4.5 L (0.99 Imp gal, 1.19 US gal) of
fuel will be remaining in the tank.
_
4-5
EBU11322
Speedometer unit
1. Speedometer 2. Odometer/Tripmeter A/Tripmeter B
3. Clock/Hour meter 4. TRIP/ODO button
5. Clock/Hour button /
6. H button 7. M button
The speedometer unit is equipped with the
following:
G a speedometer (which shows the riding
speed)
G an odometer (which shows the total dis-
tance traveled)
G two tripmeters (which show the distance
traveled since they were last set to zero)
G a clock
G an hour meter (which shows the total time
the key has been turned to ON)
4-6
Odometer and tripmeter modes
Pushing the TRIP/ODO button switches the
display between the odometer mode ODO
and the tripmeter modes A and B in the fol-
lowing order:
ODOTRIP ATRIP BODO
To reset a tripmeter, select it by pushing the
TRIP/ODO button, and then push the TRIP/
ODO button for at least three seconds. The
tripmeters can be used to estimate the dis-
tance that can be traveled with a full tank of fu-
el. This information will enable you to plan
future fuel stops.
NOTE:
_
Holding in the TRIP/ODO button and then
turning the key to ON switches the display
between mph and km/h.
_
Clock mode
Pushing the / button switches the
display between the clock mode CLOCK
and the hour meter mode HOUR in the fol-
lowing order:
CLOCKHOURCLOCK
To set the clock
1. Set the display to the clock mode.
2. Push the / button until the clock
starts flashing.
3. Set the hours by pushing the H button.
4. Set the minutes by pushing the M but-
ton.
5. Push the / button, and then re-
lease it to start the clock.
4-7
EBU00053
Handlebar switches
1. Light switch / /OFF
2. Start switch
3. Engine stop switch /
4. Override switch OVERRIDE
EBU12040
Light switch / /OFF
Set the switch to to turn on the low beam
and the taillight.
Set the switch to to turn on the high
beam and the taillight.
Set the switch to OFF to turn off all the lights.
CAUTION:
_
Do not use the headlights with the engine
turned off for more than thirty minutes.
The battery may discharge to the point
that the starter motor will not operate
properly. If this should happen, remove
the battery and recharge it.
_
EBU12050
Engine stop switch /
Make sure that the engine stop switch is set to
before starting the engine. The engine
stop switch controls ignition and can be used
at all times to stop the engine, especially in an
emergency. The engine will not start or run
when the engine stop switch is set to .
4-8
EBU00607
Start switch
The starter motor cranks the engine when this
switch is pushed.
CAUTION:
See starting instructions prior to starting
the engine. (See page 6-1 for details.)
1. Override switch OVERRIDE
EBU13781
Override switch OVERRIDE
Top speed is normally limited when operating
in 4WD-LOCK. If conditions require more en-
gine power when riding forward, push and
hold this switch to override the 4WD-LOCK
speed limiting function. (See page 4-11 for a
detailed explanation about the differential
gear lock switch and its function.) Releasing
the switch restores the speed limiting function.
While this switch is pushed, the segments of
the speedometer digits will appear as shown
in the figure.
4-9
NOTE:
_
If the digits of the speedometer appear as
shown when the switch is NOT being pushed,
this could indicate a malfunction in the electri-
cal system. In this case, take the ATV to a
Yamaha dealer at the first opportunity.
_
WARNING
POTENTIAL HAZARD
Riding too fast while the ATV is in
4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when
the differential is locked, so it takes
more effort to turn the ATV. The amount
of effort is more the faster you go. You
may lose control and have an accident if
you cannot make a sharp enough turn
for the speed you are traveling.
Always ride at a slow speed when the
ATV is in 4WD-LOCK, and allow extra
time and distance for maneuvers.
4-10
1. On-Command four-wheel drive switch 2WD/4WD
2. Differential gear lock switch LOCK/4WD
EBU14091
On-Command four-wheel drive and differ-
ential gear lock switches
This ATV is equipped with an On-Command
four-wheel drive switch 2WD/4WD and a
differential gear lock switch LOCK/4WD.
Select the appropriate drive according to ter-
rain and the conditions.
G Two-wheel drive (2WD): Power is supplied
to the rear wheels only.
G Four-wheel drive (4WD): Power is supplied
to the rear and front wheels.
G Four-wheel drive with the differential gear
locked (4WD-LOCK): Power is supplied to
the rear and front wheels when the differen-
tial gear is locked (DIFF.LOCK). Unlike
the 4WD mode, all wheels turn at the same
speed.
4-11
1. Lever
2. On-Command four-wheel drive switch 2WD/4WD
On-Command four-wheel drive switch
2WD/4WD
To change from 2WD to 4WD, stop the ATV,
and then set the switch to 4WD. When the
ATV is in 4WD, the 4WD indicator will
come on in the speedometer unit display.
To change from 4WD to 2WD, stop the ATV,
be sure the lever is set to position a, and then
set the switch to 2WD.
WARNING
POTENTIAL HAZARD
Changing from 2WD to 4WD or from
4WD to 4WD-LOCK (DIFF.LOCK), or
vice-versa while the ATV is moving.
WHAT CAN HAPPEN
The ATV handles differently in 2WD
than in 4WD and in 4WD-LOCK in some
circumstances. Changing from 2WD to
4WD or from 4WD to 4WD-LOCK, or
vice-versa while moving may cause the
ATV to unexpectedly handle differently.
This could distract the operator and in-
crease the risk of losing control and an
accident.
Always stop the ATV before changing
from 2WD to 4WD or from 4WD to
4WD-LOCK, or vice-versa.
4-12
1. Differential gear lock switch LOCK/4WD
2. Lever
Differential gear lock switch LOCK/
4WD
To lock the differential gear in 4WD, make sure
the On-Command four-wheel-drive switch is
set to 4WD, stop the ATV, move the lever to
position b, and then set the switch to LOCK.
When the differential gear is locked, the differ-
ential gear lock indicator (DIFF.LOCK) light
will come on along with the indicator in
the speedometer unit display.
To release the differential gear lock, stop the
ATV and set the switch to 4WD.
DIFF.
LOCK
WARNING
POTENTIAL HAZARD
Riding too fast while the ATV is in
4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when
the differential is locked, so it takes
more effort to turn the ATV. The amount
of effort is more the faster you go. You
may lose control and have an accident if
you cannot make a sharp enough turn
for the speed you are traveling.
Always ride at a slow speed when the
ATV is in 4WD-LOCK, and allow extra
time and distance for maneuvers.
4-13
NOTE:
_
G When the switch is set to LOCK, the dif-
ferential gear lock indicator light will flash
until the differential gear is locked.
G When the indicator light is flashing, turn-
ing the handlebar back and forth will help
the differential gear lock to engage.
G Riding before the differential gear lock is
properly engaged (e.g., when the indica-
tor light is flashing) will cause the engine
speed to be limited until engagement is
complete.
G When the ATV is in 4WD-LOCK, the
maximum traveling speed is limited to
35 km/h (22 mph). However, if conditions
require full engine power to be available,
push and hold the override switch to dis-
able the 4WD-LOCK speed limiter. (See
page 4-8 for a detailed explanation of this
switch.)
_
EBU00062
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying
the throttle position. Because the throttle is
spring-loaded, the machine will decelerate,
and the engine will return to an idle any time
the hand is removed from the throttle lever.
1. Throttle lever
4-14
Before starting the engine, check the throttle
to be sure it is operating smoothly. Make sure
it returns to the idle position as soon as the le-
ver is released.
EBU01159
Speed limiter
The speed limiter keeps the throttle from fully
opening, even when the throttle lever is
pushed to the maximum. Turning in the ad-
justing screw limits the maximum engine pow-
er available and decreases the maximum
speed of the ATV.
1. Locknut 2. Adjusting screw
a. No more than 12 mm (0.47 in)
WARNING
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate,
making it difficult to speed up or slow
down when you need to. This could
cause an accident.
Check the operation of the throttle lever
before you start the engine. If it does not
work smoothly, check for the cause.
Correct the problem before riding the
ATV. Consult a Yamaha dealer if you
cant find or solve the problem yourself.
4-15
EBU00070
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ap-
ply the front brake.
1. Front brake lever
EBU00732
Brake pedal and rear brake lever
The brake pedal is located on the right side of
the ATV and the rear brake lever is located on
the left handlebar. Push down on the pedal or
pull the lever toward the handlebar to apply
the rear brake.
WARNING
POTENTIAL HAZARD
Improper adjustment of the speed limit-
er and throttle.
WHAT CAN HAPPEN
The throttle cable could be damaged.
Improper throttle operation could result.
You could lose control, have an acci-
dent or be injured.
Do not turn the adjusting screw out
more than 12 mm (0.47 in). Always make
sure the throttle lever free play is adjust-
ed to 3.05.0 mm (0.120.20 in). See
page 8-38.
4-16
1. Brake pedal
1. Rear brake lever
EBU00608
Drive select lever
The drive select lever is used to shift your ma-
chine into the low, high, neutral, reverse and
park positions. (Refer to page 6-4 for the drive
select lever operation.)
4-17
EBU00855
Recoil starter
Firmly grasp the handle and pull slightly until
engagement can be felt. Then pull forcefully,
being careful not to pull the rope all the way
out.
1. Recoil starter
WARNING
POTENTIAL HAZARD
Starting the engine without setting the
drive select lever to the park position
P.
WHAT CAN HAPPEN
The ATV could start to move unexpect-
edly, which could cause an accident.
Set the drive select lever to the park po-
sition before starting the engine.
4-18
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it coun-
terclockwise.
1. Fuel tank cap
EBU00930
Fuel cock
The fuel cock supplies fuel from the fuel tank
to the carburetor.
The fuel cock has three positions.
OFF: With the lever in this position, fuel will
not flow. Always turn the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, turn the lever to this
position. THEN FILL THE FUEL TANK
AT THE FIRST OPPORTUNITY. After
refuelling, return the fuel cock lever to
the ON position.
4-19
1. Arrow mark pointing to OFF
1. Arrow mark pointing to ON
1. Arrow mark pointing to RES
OFF Position
ON Position
RES Position
4-20
EBU00095
Starter (choke)
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction a to turn on the starter
(choke).
Move in direction b to turn off the starter
(choke).
Refer to Starting a cold engine for proper op-
eration. (See page 6-1.)
1. Starter (choke)
EBU05670
Seat
To remove the seat, pull the seat lock lever
upward and pull up the seat at the rear.
1. Seat 2. Seat lock lever
4-21
To install the seat, insert the projections on
the front of the seat into the seat holders and
push down on the seat at the rear.
NOTE:
_
Make sure that the seat is securely fitted.
_
1. Projection ( 2) 2. Seat holder ( 2)
EBU15230
Storage compartment
The storage compartment is located under
the seat. (See page 4-20 for seat removal and
installation procedures.)
When storing any documents in the storage
compartment, be sure to wrap them in a plas-
tic bag so that they will not get wet. When
washing the ATV, be careful not to let any wa-
ter enter the storage compartment.
NOTE:
_
There is a check hose at the bottom of the
storage compartment. If any water collects in
this hose, remove the hose, empty it, and then
install it.
_
Maximum load limit: 2.0 kg (4 lb)
4-22
1. Storage compartment
1. Storage compartment check hose
EBU00582
Front carrier
EBU00583
Rear carrier
Maximum load limit: 40 kg (88 lb)
Maximum load limit: 80 kg (176 lb)
4-23
EBU15220
Front and rear shock absorber adjustment
The spring preload can be adjusted to suit the
riders weight and riding conditions.
Adjust the spring preload as follows.
To increase the spring preload, turn the ad-
justing ring in direction a.
To decrease the spring preload, turn the ad-
justing ring in direction b.
1. Spring preload adjusting ring
2. Position indicator
NOTE:
_
A special wrench can be obtained at a
Yamaha dealer to make this adjustment.
_
Standard position: 2
1- Minimum (soft)
5- Maximum (hard)
4-24
1. Special wrench
WARNING
POTENTIAL HAZARD
Improper shock absorber adjustment.
WHAT CAN HAPPEN
Uneven adjustment can cause poor
handling and loss of stability, which
could lead to an accident.
Always adjust the shock absorbers on
the left and right side to the same set-
ting.
4-25
EBU10020
Auxiliary DC jack
The auxiliary DC jack is located at the front
right side of the ATV.
The auxiliary DC jack can be used for suitable
work lights, radios, etc.
The auxiliary DC jack should only be used
when the engine is running.
1. Set the light switch to OFF.
1. Auxiliary DC jack cap
2. Start the engine. (See pages 6-16-3.)
3. Open the auxiliary DC jack cap, and then
insert the accessory power plug into the
jack.
4. When the auxiliary DC jack is not being
used, cover it with the cap.
CAUTION:
_
G Do not use accessories requiring
more than the above maximum capac-
ity. This may overload the circuit and
cause the fuse to blow.
G If accessories are used without the
engine running or with the headlights
turned on, the battery will lose its
charge and engine starting may be-
come difficult.
G Do not use an automotive cigarette
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
_
Maximum rated capacity for the auxiliary
DC jack:
DC 12 V, 120 W (10 A)
4-26
1. Auxiliary DC jack
EBU00112
WARNING
5-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1- PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brake
Check operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.
5-25-3, 8-398-43
Rear brake
Check operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.
5-25-3, 8-408-45
Fuel
Check fuel level.
Fill with fuel if necessary.
5-45-5
Engine oil
Check oil level.
Fill with oil if necessary.
5-6, 8-128-17
Coolant reservoir
Check coolant level in reservoir.
Fill with coolant if necessary.
5-7, 8-228-27
Final gear oil and
differential gear oil
Check for leakage. 5-6, 8-178-22
Throttle Check for proper throttle cable operation and free play. 5-7, 8-38
Wheels and tires Check tire pressure, wear and damage. 5-85-11, 8-498-50
Fittings and fasteners Check all fittings and fasteners. 5-8
Lights and switches Check for proper operation. 5-8, 8-45, 8-548-59
Axle boots Check for damage. 8-278-28
5-2
EBU11011
Front and rear brakes
Brake levers and brake pedal
G Check that there is no free play in the front
brake lever. If there is free play, have a
Yamaha dealer adjust it.
G Check for correct free play in the rear brake
lever. If the free play is incorrect, adjust it.
(See pages 8-448-45.)
G Check for correct brake pedal height. If the
pedal height is incorrect, have a Yamaha
dealer adjust it.
G Check the operation of the brake levers
and pedal. They should move smoothly
and there should be a firm feeling when the
brakes are applied. If not, have a Yamaha
dealer inspect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if neces-
sary. (See pages 8-418-42.)
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before oper-
ating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
Always inspect your ATV each time you
use it to make sure the ATV is in safe op-
erating condition.
Always follow the inspection and main-
tenance procedures and schedules de-
scribed in the Owners Manual.
Recommended brake fluid: DOT 4
5-3
Brake fluid leakage
Check to see if any brake fluid is leaking out of
the pipe joints or brake fluid reservoirs. Apply
the brakes firmly for one minute. If the lever
moves slowly inward, there may be a leak in
the brake system. If there is any leakage, the
brake system should be inspected by a
Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking per-
formance, inspect the brake pads for wear.
(See pages 8-398-40.)
WARNING
POTENTIAL HAZARD
Riding with improperly operating
brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
Always check the brakes at the start of
every ride. Do not ride the ATV if you
find any problem with the brakes. If a
problem cannot be corrected by the ad-
justment procedures provided in this
manual, have a Yamaha dealer check for
the cause.
5-4
EBU01085
Fuel
Make sure there is sufficient gasoline in the
tank.
CAUTION:
_
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to internal engine parts, such as the valves
and piston rings, as well as to the exhaust
system.
_
Your Yamaha engine has been designed to
use regular unleaded gasoline with a pump
octane number ([R+M]/2) of 86 or higher, or
research octane number of 91 or higher. If
knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Unleaded fuel will give you longer spark plug
life and reduced maintenance cost.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total:
15.0 L (3.30 Imp gal, 3.96 US gal)
Reserve:
4.5 L (0.99 Imp gal, 1.19 US gal)
5-5
Gasohol
There are two types of gasohol; gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if
ethanol content does not exceed 10%. Gaso-
hol containing methanol is not recommended
by Yamaha because it may cause fuel system
damage or vehicle performance problems.
1. Fuel level 2. Fuel tank filler tube
WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire
and severe injury.
Fuel expands when it heats up. If the
fuel tank is overfilled, fuel could spill out
due to heat from the engine or the sun.
Do not overfill the fuel tank. Be careful
not to spill fuel, especially on the engine
or exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Do not refuel right after the engine has
been running and is still very hot.
5-6
EBU10842
Engine oil
Make sure the engine oil is at the specified
level. Add oil as necessary. (See pages 8-12
8-17.)
CAUTION:
_
G In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of CD or oils of a high-
er quality than specified. In addition,
do not use oils labeled ENERGY
CONSERVING II or higher.
G Make sure that no foreign material en-
ters the crankcase.
_
EBU00493
Final gear oil
Make sure the final gear oil is at the specified
level. Add oil as necessary. (See pages 8-17
8-20 for details.)
If desired, an SAE 80W90 hypoid gear oil may
be used for all conditions.
NOTE:
GL-4 is a quality and additive rating, GL-5 or
GL-6 rated hypoid gear oils may also be used.
EBU00678
Differential gear oil
Make sure the differential gear oil is at the
specified level. Add oil as necessary. (See
pages 8-208-22 for details.)
Recommended engine oil type and
quantity:
See page 10-2.
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Recommended oil:
5-7
EBU12530
Coolant
Check the coolant level in the coolant reser-
voir when the engine is cold. (The coolant lev-
el will vary with engine temperature.) The
coolant level is satisfactory if it is between the
minimum and maximum level marks on the
coolant reservoir. If the coolant level is at or
below the minimum level mark, add distilled
water to bring the level up to maximum level
mark. Change the coolant every two years.
(See pages 8-228-27 for details.)
CAUTION:
_
Hard water or salt water is harmful to the
engine. You may use soft water if you can-
not get distilled water.
_
EBU01083
Throttle lever
Check to see that the throttle lever operates
correctly. It must open smoothly and spring
back to the idle position when released. Have
a Yamaha dealer repair as necessary for
proper operation.
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L (0.22 Imp qt, 0.26 US qt)
WARNING
POTENTIAL HAZARD
Removing the radiator cap when the en-
gine and radiator are still hot.
WHAT CAN HAPPEN
You could be burned by hot fluid and
steam blown out under pressure.
Wait for the engine to cool before re-
moving the radiator cap. Always use a
thick rag over the cap. Allow any re-
maining pressure to escape before
completely removing the cap.
5-8
EBU11620
Fittings and fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine
to a Yamaha dealer or refer to the Service
Manual for correct tightening torque.
EBU10030
Lights
Check the headlights and tail/brake light to
make sure they are in working condition. Re-
pair as necessary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.
EBU00157
Tires
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire pres-
sure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or op-
eration of this ATV with improper or un-
even tire pressure, may cause loss of
control, increasing your risk of acci-
dent.
1. The tires listed below have been ap-
proved by Yamaha Motor Co., Ltd.
for this model. Other tire combina-
tions are not recommended.
ACE-01E
Manufacturer Size Type
Front MAXXIS AT25 8-12 M911Y
Rear MAXXIS AT25 10-12 M912Y
5-9
2. The tires should be set to the rec-
ommended pressure:
G Recommended tire pressure
Front 25 kPa (0.25 kgf/cm
2
, 3.6 psi)
Rear 25 kPa (0.25 kgf/cm
2
, 3.6 psi)
G Check and adjust tire pressures when
the tires are cold.
G Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum
specified could cause the tire to
dislodge from the rim under severe
riding conditions.
The following are minimums:
2
, 3.2 psi)
2
, 3.2 psi)
4. Use no more than the following
pressures when seating the tire
beads.
2
, 36 psi)
2
, 36 psi)
Higher pressures may cause the
tire to burst. Inflate the tires very
slowly and carefully. Fast inflation
could cause the tire to burst.
5-10
EBU00159
How to measure tire pressure
Use the low-pressure tire gauge.
NOTE:
The low-pressure tire gauge is included as
standard equipment. Make two measure-
ments of the tire pressure and use the second
reading. Dust or dirt in the gauge could cause
the first reading to be incorrect.
Set pressure with tires cold.
Set tire pressures to the following specifica-
tions:
ACE-02EACE-02E
1. Low-pressure tire gauge
Recommended
pressure
Minimum Maximum
Front
25 kPa
(0.25 kgf/cm
2
,
3.6 psi)
22 kPa
(0.22 kgf/cm
2
,
3.2 psi)
28 kPa
(0.28 kgf/cm
2
,
4.0 psi)
Rear
25 kPa
(0.25 kgf/cm
2
,
3.6 psi)
22 kPa
(0.22 kgf/cm
2
,
3.2 psi)
28 kPa
(0.28 kgf/cm
2
,
4.0 psi)
5-11
EBU00160
Tire wear limit
When the tire groove decreases to 3 mm
(0.12 in) due to wear, replace the tire.
a. Tire wear limit
6-1
EBU00161
1-OPERATION
WARNING
EBU15110
Starting a cold engine
1. Apply the rear brake lever or brake pedal.
2. Turn the fuel cock to ON.
3. Turn the main switch to ON and the en-
gine stop switch to .
4. Shift the drive select lever into the neutral
or park position.
WARNING
POTENTIAL HAZARD
Operating ATV without being familiar
with all controls.
WHAT CAN HAPPEN
Loss of control, which could cause an
accident or injury.
Read the Owners Manual carefully. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or colli-
sion.
When riding in cold weather, always
make sure all control cables work
smoothly before you begin riding.
6-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
NOTE:
_
G When the drive select lever is in the neu-
tral or park position, if either indicator light
does not come on, ask a Yamaha dealer
to inspect the respective electric circuit.
G The engine can be started in any gear if
the rear brake lever or brake pedal is ap-
plied. However, it is recommended to
shift into neutral or park before starting
the engine.
_
5. Use the starter (choke) in reference to
the figure:
Position 1 : Cold engine start-
ambient temperature below 5 C
(40 F).
ambient temperature at 0 C
(30 F)30 C (90 F) and
warming up position.
ambient temperature above
25 C (80 F) and warm engine
start position.
a. Starter (choke) 1. Fully open
2. Half open 3. Closed
6. Completely close the throttle lever and
start the engine by pushing the start
switch.
6-3
NOTE:
_
G If the engine fails to start, release the
start switch, then push the start switch
again. Pause a few seconds before the
next attempt. Each cranking should be as
short as possible to preserve battery en-
ergy. Do not crank the engine more than
10 seconds on each attempt.
G If the battery is discharged, pull the recoil
starter to start the engine.
_
7. If the engine is started with the starter
(choke) in position 1, the starter (choke)
should be returned to position 2 to warm
up the engine. If the engine is started with
the starter (choke) in position 2, keep
the starter (choke) in this position to
warm up the engine.
8. Continue warming up the engine until it
idles smoothly and return the starter
(choke) to position 3 before riding.
CAUTION:
_
See the Engine break-in section prior to
operating the engine for the first time.
_
EBU00180
Starting a warm engine
To start a warm engine, refer to the Starting a
cold engine section. The starter (choke)
should not be used. The throttle should be
opened slightly.
EBU00182
Warming up
To get maximum engine life, always warm up
the engine before starting off. Never acceler-
ate hard with a cold engine! To see whether or
not the engine is warm, check if it responds to
the throttle normally with the starter (choke)
turned off.
6-4
EBU08461
Drive select lever operation and reverse
driving
CAUTION:
_
Before shifting, you must stop the ATV
and return the throttle lever to the closed
position, otherwise the transmission may
be damaged.
_
Shifting: Neutral to High and High to Low
1. Bring the ATV to a complete stop and re-
turn the throttle lever to the closed posi-
tion.
2. Apply the brakes, then shift by moving
the drive select lever along the shift
guide.
NOTE:
_
Make sure that the drive select lever is com-
pletely shifted into position.
_
3. Open the throttle lever gradually.
6-5
Shifting: Neutral to Reverse and Reverse
to Park
NOTE:
_
The drive select lever cannot be shifted into or
from reverse or park without applying the rear
brake.
_
1. Bring the ATV to a complete stop and re-
turn the throttle lever to the closed posi-
tion.
2. Apply the brake pedal.
3. Shift from neutral to reverse or from re-
verse to park and vice versa by moving
the drive select lever along the shift
guide.
NOTE:
_
G When in reverse, the reverse indicator
light should be on. If the light does not
come on, ask a Yamaha dealer to inspect
the electrical circuit.
G Due to the synchronizing mechanism in
the engine, the light may not come on un-
til the ATV starts moving.
_
4. Check behind for people or obstacles,
and then release the brake pedal.
6-6
5. Open the throttle lever gradually and con-
tinue to watch to the rear while backing.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person be-
hind you, resulting in serious injury.
When you shift into reverse, make sure
there are no obstacles or people behind
you. When it is safe to proceed, go slow-
ly.
6-7
EBU02101
Engine break-in
There is never a more important period in the
life of your machine than the period between
zero and 20 hours.
For this reason, we ask that you carefully read
the following material. Because the engine is
brand new, you must not put an excessive
load on it for the first several hours of running.
During the first 20 hours, the various parts in
the engine wear and polish themselves to the
correct operating clearances.
During this period, prolonged full throttle oper-
ation or any condition which might result in ex-
cessive engine heating must be avoided.
However, momentary (23 seconds maxi-
mum) full throttle operation under load does
not harm the engine.
Each full throttle acceleration sequence
should be followed with a substantial rest pe-
riod for the engine by cruising at lower r/min
so the engine can rid itself of the temporary
build up of heat.
If any abnormality is noticed during this peri-
od, consult a Yamaha dealer.
010 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten min-
utes after every hour of operation. Vary the
speed of the machine from time to time. Do
not operate it at one set throttle position.
6-8
1020 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00612
Parking
When parking, stop the engine and shift the
drive select lever into the park position, then
turn the fuel cock to the OFF position.
6-9
EBU06151
Parking on a slope 1. Bring the machine to a stop by applying
the brakes.
2. Stop the engine.
3. With the brake pedal applied, shift the
drive select lever to the park position P.
WARNING
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, in-
creasing the chance of an accident.
Avoid parking on hills or other inclines.
If you must park on an incline, place the
machine transversely across the in-
cline, apply the parking brake, and block
the front and rear wheels with rocks or
other objects.
Do not park the ATV at all on hills that
are so steep you could not walk up them
easily.
6-10
EBU00221
Accessories and loading
EBU00222
Accessories
Accessories can affect the handling and con-
trol of your ATV. Keep the following in mind
when considering an accessory or operating
an ATV which has accessories.
G Choose only accessories designed for your
ATV. Your Yamaha dealer has a variety of
genuine Yamaha accessories. Other ac-
cessories may also be available on the
market. However, it is not possible for
Yamaha to test all non-Yamaha accesso-
ries, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equiva-
lent in design and quality.
G Accessories should be rigidly and securely
mounted. An accessory which can shift po-
sition or come off while you are riding could
affect your ability to control the ATV.
G Do not mount an accessory where it could
interfere with your ability to control the ATV.
Examples include (but are not limited to) a
heavy or bulky object attached to the han-
dlebars which could make steering difficult,
an accessory that limits your ability to move
around on the seat, or one that limits your
view.
G Use extra caution when riding an ATV with
accessories. The ATV may handle differ-
ently than it does without accessories.
6-11
EBU15260
Loading
Cargo or a trailer can change the stability and
handling of an ATV. You must use common
sense and good judgment when carrying car-
go or towing a trailer. Keep the following
points in mind:
G Never exceed the weight limits shown. An
overloaded ATV can be unstable.
G Do not exceed the maximum tongue
weight. You can measure tongue weight
with a bathroom scale. Put the tongue of
the loaded trailer on the scale with the
tongue at hitch height. Adjust the load in the
trailer, if necessary, to reduce the weight on
hitch.
If you are carrying cargo and towing a trail-
er, include the tongue weight in the maxi-
mum vehicle load limit.
G Load cargo on the carrier as close to the
center of the vehicle as possible. Put cargo
at the rear of the front carrier and at the
front of the rear carrier. Center the load
from side to side.
G Tie down cargo securely to the carriers.
Make sure cargo in the trailer cannot move
around. A shifting load can cause an acci-
dent.
G Make sure the load does not interfere with
controls or your ability to see where you are
going.
MAXIMUM LOADING LIMIT
G Vehicle loading limit (total weight of
cargo, rider and accessories, and
tongue weight): 210 kg (463 lb)
G Front carrier: 40 kg (88 lb)
G Rear carrier: 80 kg (176 lb)
G Storage compartment: 2.0 kg (4 lb)
G Trailer hitch:
Pulling load (total weight of trailer and
cargo): 500 kgf (1,102 lbf)
Tongue weight (vertical weight on
trailer hitch point): 15 kgf (33 lbf)
6-12
G Ride more slowly than you would without a
load. The more weight you carry, the slow-
er you should go. Although conditions vary,
it is good practice not to exceed low range
whenever you are carrying heavier loads or
when towing a trailer.
G Allow more braking distance. A heavier ve-
hicle takes longer to stop.
G Avoid making sharp turns unless at very
slow speeds.
G Avoid hills and rough terrain. Choose ter-
rain carefully. Added weight affects the sta-
bility and handling of the ATV.
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle han-
dling which could lead to an accident.
Never exceed the stated load capacity
for this ATV.
Cargo should be properly distributed
and securely attached. Reduce speed
when carrying cargo or pulling a trailer.
Allow greater distance for braking.
6-13
EBU15280
WARNING
_
7-1
7
1-Riding
Your
ATV
7-3
WARNING
_
GETTING TO KNOW YOUR ATV
This ATV is for recreation and utility use. This
section, Riding your ATV, provides general
ATV riding instructions for recreational riding.
The skills and techniques described in this
section, however, are appropriate for all types
of riding. Riding your ATV requires special
skills acquired through practice over a period
of time. Take the time to learn the basic tech-
niques well before attempting more difficult
maneuvers.
Riding your new ATV can be a very enjoyable
activity, providing you with hours of pleasure.
But it is essential to familiarize yourself with
the operation of the ATV to achieve the skill
necessary to enjoy riding safely. Before you
begin to ride, be sure you have read this
Owners Manual completely and understand
the operation of the controls. Pay particular at-
tention to the safety information on pages
2-12-6. Please also read all caution and
warning labels on your ATV.
7-4
RIDE WITH CARE AND GOOD
JUDGEMENT
Get training if you are inexperienced.
Beginners should get training from a certified
instructor.
Become familiar with this ATV at slow speeds
first, even if you are an experienced operator.
Do not attempt to operate at maximum perfor-
mance until you are totally familiar with the
ATVs handling and performance characteris-
tics.
Riding your ATV requires skills acquired
through practice over a period of time.
Take the time to learn the basic techniques
well before attempting more difficult maneu-
vers.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper in-
struction.
WHAT CAN HAPPEN
The risk of an accident is greatly in-
creased if the operator does not know
how to operate the ATV properly in dif-
ferent situations and on different types
of terrain.
Beginning and inexperienced operators
should complete the certified training
course offered by Yamaha. They should
then regularly practice the skills learned
in the course and the operating tech-
niques described in this Owners Manu-
al. For more information about the
training course, contact an authorized
ATV dealer or call 1-800-887-2887.
7-5
Not recommended for children under
16 years of age.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommenda-
tions for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not rec-
ommended for their age can lead to se-
vere injury or death of the child.
A child under 16 should never operate
an ATV with engine size greater than
90cc.
7-6
This ATV is designed to carry operator and
cargo only passengers prohibited.
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance
and control this ATV. Could cause an
accident, resulting in harm to you and/
or your passenger.
Never carry a passenger. The long seat
is to allow the operator to shift position
as needed during operation. It is not for
carrying passengers.
7-7
Apparel
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye pro-
tection and protective clothing.
WHAT CAN HAPPEN
Operating without
an approved motor-
cycle helmet in-
creases your
chances of a severe
head injury or death
in the event of an ac-
cident.
Operating without eye protection can re-
sult in an accident and increases your
chances of a severe injury in the event
of an accident.
Operating without protective clothing
increases your chances of severe injury
in the event of an accident.
Always wear an approved motorcycle
helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
7-8
Do not operate after consuming alcohol or
drugs.
Operators performance capability is reduced
by the influence of alcohol or drugs.
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming al-
cohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and percep-
tion.
Could result in an accident.
Never consume alcohol or drugs before
or while driving this ATV.
7-9
Pre-operation checks
Always perform the pre-operation checks list-
ed on page 5-1 before riding for safety and
proper care of the ATV.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before oper-
ating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
Always inspect your ATV each time you
use it to make sure the ATV is in safe op-
erating condition.
Always follow the inspection and main-
tenance procedures and schedules de-
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire pres-
sure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or op-
eration of this ATV with improper or un-
even tire pressure, may cause loss of
control, increasing your risk of an acci-
dent.
Always use the size and type tires spec-
ified in the Owners Manual for this vehi-
cle on pages 5-85-9.
Always maintain proper tire pressure as
described in the Owners Manual on
page 5-10.
7-10
WARNING
_
Do not operate at speeds too fast for your
skills or the conditions.
Speed limiter
For riders less experienced with this model,
this model is equipped with a speed limiter in
the throttle lever housing. The speed limiter
keeps the throttle from fully opening, even
when the throttle lever is pushed to the maxi-
mum. Turning in the adjusting screw limits the
maximum engine power available and de-
creases the maximum speed of the ATV.
Turning the adjusting screw in decreases top
speed and turning it out increases top speed.
(See pages 4-144-15 for details.)
1. Locknut 2. Adjusting screw
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast
for your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing con-
trol of the ATV, which can result in an
accident.
Always go at a speed that is proper for
the terrain, visibility and operating con-
ditions, and your experience.
7-11
Loading and accessories
Use extra caution when riding the ATV with
additional loads, such as accessories or car-
go. The ATVs handling may be adversely af-
fected. Reduce your speed when adding
additional loads.
MAXIMUM LOADING LIMIT
G Vehicle loading limit: 210 kg (463 lb)
* Total weight of cargo, rider and
accessories, and trailer hitch
vertical load.
G Front carrier: 40 kg (88 lb)
G Rear carrier: 80 kg (176 lb)
G Storage compartment: 2.0 kg (4 lb)
G Trailer hitch:
Pulling load: 500 kgf (1,102 lbf)
Total weight of trailer and cargo.
Tongue weight: 15 kgf (33 lbf)
Vertical weight on trailer hitch point.
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle han-
dling which could lead to an accident.
Never exceed the stated load capacity
for this ATV.
Cargo should be properly distributed
and securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.
Always follow the instructions in your
Owners Manual for carrying cargo or
pulling a trailer.
7-12
During operation
Always keep your feet on the footboards dur-
ing operation. Otherwise your feet may con-
tact the rear wheels.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars or
feet from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can re-
duce your ability to control the ATV or
could cause you to lose your balance
and fall off of the ATV. If you remove a
foot from a footboard, your foot or leg
may come into contact with the rear
wheels, which could injure you or cause
an accident.
Always keep both hands on the handle-
bars and both feet on the footboards of
your ATV during operation.
7-13
Avoid wheelies and jumping. You may lose
control of the ATV or overturn.
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, in-
cluding an overturn.
Never attempt stunts, such as wheelies
or jumps. Dont try to show off.
7-14
Modifications
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modi-
fications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situ-
ations could lead to an accident.
Never modify this ATV through improp-
er installation or use of accessories. All
parts and accessories added to this ve-
hicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed
and used according to instructions. If
you have questions, consult an autho-
rized ATV dealer.
7-15
Exhaust system
The exhaust system on the ATV is very hot
during and following operation. To prevent
burns, avoid touching the exhaust system.
Park the ATV in a place where pedestrians or
children are not likely to touch it.
WARNING
POTENTIAL HAZARD
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible
material accumulated around the en-
gine area could catch fire.
Someone touching the exhaust system
during or after operation could be
burned.
Do not operate, idle, or park the ATV in
dry grass or other dry ground cover.
Keep the engine area free of dry grass,
brush, or other combustible material.
Do not touch the hot exhaust system.
Do not park the ATV in a place where
others might be likely to touch it.
7-16
BE CAREFUL WHERE YOU RIDE
This ATV is designed for off-road use only.
Riding on paved surfaces can cause loss of
control.
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
ATVs are designed for off-road use only.
Paved surfaces may seriously affect
handling and control of the ATV, and
may cause the vehicle to go out of con-
trol.
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
7-17
Do not ride on any public road, street, or high-
way.
Riding on public roads can result in collisions
with other vehicles.
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets,
roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
Never operate this ATV on any public
street, road or highway, even a dirt or
gravel one. In many states it is illegal to
operate ATVs on public streets, roads
and highways.
7-18
Know the terrain where you ride. Ride cau-
tiously in unfamiliar areas. Stay alert for
holes, rocks, or roots in the terrain, and oth-
er hidden hazards which may cause the ATV
to upset.
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
this ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks,
bumps, or holes, without enough time to
react. Could result in the ATV overturn-
ing or going out of control.
Go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be
alert to changing terrain conditions
when operating the ATV.
7-19
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
on excessively rough, slippery or loose
terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle
control, which could result in an acci-
dent, including an overturn.
Do not operate on excessively rough,
slippery or loose terrain until you have
learned and practiced the skills neces-
sary to control the ATV on such terrain.
Always be especially cautious on these
kinds of terrain.
7-20
When riding in an area where you might not
easily be seen, such as desert terrain, mount
a caution flag on the ATV. DO NOT use the
flag pole bracket as a trailer hitch.
Do not ride in areas posted no trespassing.
Do not ride on private property without getting
permission.
WARNING
POTENTIAL HAZARD
Operating in areas where you might not
be seen by other off-road vehicles.
WHAT CAN HAPPEN
You could be in a collision. You could
be injured.
Always mount a caution flag on the ATV
to make you more visible. Watch care-
fully for other vehicles.
7-21
Select a large, flat area off-road to become fa-
miliar with your ATV. Make sure that this area
is free of obstacles and other riders. You
should practice control of the throttle, brakes,
shifting procedures, and turning techniques in
this area before trying more difficult terrain. Al-
ways avoid riding on paved surfaces: the ATV
is designed for off-road use only, and han-
dling maneuvers are more difficult to perform
on pavement.
Shift to the parking position P and follow the
instruction on page 6-1 to start the engine.
Once it has warmed up you are ready to begin
riding your ATV. Remember that the engine
and exhaust pipe will be hot when riding and
afterwards; do not allow skin or clothing to
come in contact with these components.
With the engine idling, shift the drive select le-
ver to the low position L or the high position
H. Apply the throttle slowly and smoothly.
The centrifugal clutch will engage and you will
start to accelerate. If the throttle is applied too
abruptly, the front wheels may lift off the
ground resulting in a loss of directional con-
trol. Avoid higher speeds until you are thor-
oughly familiar with the operation of your ATV.
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. Improper use of the brakes can cause
the tires to lose traction, reducing control and
increasing the possibility of an accident.
CAUTION:
_
Do not shift from drive position low L to
high H or vice versa without coming to a
complete stop. Damage to the engine or
drive train may occur.
_
7-22
TURNING YOUR ATV
To achieve maximum traction while riding off-
road in 2WD or 4WD, the two rear wheels are
mounted solidly on one axle and turn together
at the same speed. Furthermore, when riding
in 4WD-LOCK (DIFF. LOCK), the front
wheels also turn together at the same speed.
Therefore, unless the wheel on the inside of
the turn is allowed to slip or lose some trac-
tion, the ATV will resist turning. A special turn-
ing technique must be used to allow the ATV
to make turns quickly and easily. It is essential
that this skill be learned first at low speed.
As you approach a curve, slow down and be-
gin to turn the handlebars in the desired direc-
tion. As you do so, put your weight on the
footboard to the outside of the turn (opposite
your desired direction) and lean your upper
body into the turn. Use the throttle to maintain
an even speed through the turn. This maneu-
ver will let the wheel on the inside of the turn
slip slightly, allowing the ATV to make the turn
properly.
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a
collision or overturn.
Always follow proper procedures for
turning as described in this Owners
Manual.
Practice turning at low speeds before at-
tempting to turn at faster speeds. Do not
turn at speeds too fast for your skills or
the conditions.
Operate at a slow speed and allow extra
time and distance for maneuvers when
in 4WD-LOCK (DIFF. LOCK).
7-23
This procedure should be practiced at slow
speed many times in a large off-road area
with no obstacles. If an incorrect technique is
used, your ATV may continue to go straight. If
the ATV doesnt turn, come to a stop and then
practice the procedure again. If the riding sur-
face is slippery or loose, it may help to posi-
tion more of your weight over the front wheels
by moving forward on the seat.
Once you have learned this technique you
should be able to perform it at higher speeds
or in tighter curves.
Improper riding procedures such as abrupt
throttle changes, excessive braking, incorrect
body movements, or too much speed for the
sharpness of the turn may cause the ATV to
tip. If the ATV begins to tip over to the outside
while negotiating a turn, lean more to the in-
side. It may also be necessary to gradually let
off on the throttle and steer to the outside of
the turn to avoid tipping over.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your
ATV.
7-24
CLIMBING UPHILL
Use proper riding techniques to avoid vehicle
overturns on hills. Be sure that you can ma-
neuver your ATV well on flat ground before at-
tempting any incline and then practice riding
first on gentle slopes. Try more difficult climbs
only after you have developed your skill. In all
cases avoid inclines with slippery or loose sur-
faces, or obstacles that might cause you to
lose control.
It is important when climbing a hill to make
sure that your weight is transferred forward on
the ATV. This can be accomplished by lean-
ing forward and, on steeper inclines, standing
on the footboards and leaning forward over
the handlebars.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on
extremely steep hills than on level sur-
faces or small hills.
Never operate the ATV on hills too steep
for the ATV or for your abilities. Practice
on smaller hills before attempting large
hills.
7-25
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
Always follow proper procedures for
climbing hills as described in this Own-
ers Manual.
Always check the terrain carefully be-
fore you start up any hill.
Never climb hills with excessively slip-
pery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly.
The ATV could flip over backwards.
Never go over the top of any hill at high
speed.
An obstacle, a sharp drop, or another
vehicle or person could be on the other
side of the hill.
7-26
If you are climbing a hill and you find that you
have not properly judged your ability to make
it to the top, you should turn the ATV around
while you still have forward motion (provided
you have the room to do so) and go down the
hill.
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on
hills.
WHAT CAN HAPPEN
ATV to overturn.
Never attempt to turn the ATV around
on any hill until you have mastered the
turning technique as described in the
Owners Manual on level ground. Be
very careful when turning on any hill.
Avoid crossing the side of a steep hill if
possible.
7-27
When crossing the side of a hill:
Always follow proper procedures as de-
Avoid hills with excessively slippery or
loose surfaces.
Shift your weight to the uphill side of the
ATV.
7-28
If your ATV has stalled or stopped and you
believe you can continue up the hill, restart
carefully to make sure you do not lift the front
wheels which could cause you to lose control.
If you are unable to continue up the hill, dis-
mount the ATV on the uphill side. Physically
turn the ATV around and then descend the
hill.
If you start to roll backwards, DO NOT apply
either brake abruptly. If you are in 2WD, apply
only the front brake. When this ATV is in 4WD
or 4WD-LOCK, all wheels (front and rear) are
interconnected by the drive train. This means
that applying either the front brake or the rear
brake will brake all wheels. When descending
hills, using either brake lever or the brake ped-
al will brake the wheels on the downhill side.
Avoid sudden application of either the front or
rear brake because the wheels on the uphill
side could come off the ground. The ATV
could easily tip over backwards. Apply both
the front and rear brakes gradually, or dis-
mount the ATV immediately on the uphill side.
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improper-
ly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
Use proper gear and maintain steady
speed when climbing a hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Shift to the parking position P after
you are stopped.
7-29
If you begin rolling backwards:
Keep weight uphill.
2WD: Never apply the rear brake
while rolling backwards. Apply the
front brake. When fully stopped, shift
to the parking position P.
4WD or 4WD-LOCK: Apply both front
and rear brakes gradually. When fully
stopped, shift to the parking position
P.
Dismount on uphill side or to a side if
pointed straight uphill. Turn the ATV
around and remount, following the pro-
cedure described in the Owners Manu-
al.
7-30
RIDING DOWNHILL
When riding your ATV downhill, shift your
weight as far to the rear and uphill side of the
ATV as possible. Move back on the seat and
sit with your arms straight. Engine compres-
sion will do most of the braking for you. For
maximum engine compression braking effect,
select low range L and change to 4WD or
4WD-LOCK before beginning to descend the
hill. Improper braking may cause a loss of
traction. Use caution while descending a hill
with loose or slippery surfaces. Braking ability
and traction may be adversely affected by
these surfaces. Improper braking may also
cause a loss of traction.
When this ATV is in 4WD or 4WD-LOCK, all
wheels (front and rear) are interconnected by
the drive train. This means that applying either
the front brake or the rear brake will brake all
wheels. When descending hills, using either
brake lever or the brake pedal will brake the
wheels on the downhill side. Avoid sudden
application of either the front or rear brake be-
cause the wheels on the uphill side could
come off the ground. Apply both the front and
rear brakes gradually.
Whenever possible, ride your ATV straight
downhill. Avoid sharp angles which could al-
low the ATV to tip or roll over. Carefully
choose your path and ride no faster than you
will be able to react to obstacles which may
appear.
7-31
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
ATV to overturn.
Always follow proper procedures for go-
ing down hills as described in this Own-
ers Manual. Note: a special technique is
required when braking as you go down
a hill.
Always check the terrain carefully be-
fore you start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that
would cause the vehicle to lean sharply
to one side. Go straight down the hill
where possible.
7-32
CROSSING A SLOPE
Traversing a sloping surface on your ATV re-
quires you to properly position your weight to
maintain proper balance. Be sure that you
have learned the basic riding skills on flat
ground before attempting to cross a sloping
surface. Avoid slopes with slippery surfaces
or rough terrain that may upset your balance.
As you travel across a slope, lean your body
in the uphill direction. It may be necessary to
correct the steering when riding on loose sur-
faces by pointing the front wheels slightly up-
hill. When riding on slopes be sure not to
make sharp turns either up or down hill.
If your ATV does begin to tip over, gradually
steer in the downhill direction if there are no
obstacles in your path. As you regain proper
balance, gradually steer again in the direction
you wish to travel.
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on
hills.
WHAT CAN HAPPEN
ATV to overturn.
Never attempt to turn the ATV around
on any hill until you have mastered the
turning technique as described in the
Owners Manual on level ground. Be
very careful when turning on any hill.
Avoid crossing the side of a steep hill if
possible.
When crossing the side of a hill:
Always follow proper procedures as de-
Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the
uphill side of the ATV.
7-33
7-34
CROSSING THROUGH SHALLOW WATER
The ATV can be used to cross slow moving,
shallow water of up to a maximum of 35 cm
(14 inches) in depth. Before entering the wa-
ter, choose your path carefully. Enter where
there is no sharp drop off, and avoid rocks or
other obstacles which may be slippery or up-
set the ATV. Drive slowly and carefully.
WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction
and loss of control, which could lead to
an accident.
Never operate this ATV in fast flowing
water or in water deeper than that spec-
ified in your Owners Manual.
Remember that wet brakes may have re-
duced stopping ability. Test your brakes
after leaving water. If necessary, apply
them several times to let friction dry out
the linings.
7-35
Test your brakes after leaving the water. Do
not continue to ride your ATV without verifying
that you have regained proper braking ability.
CAUTION:
_
After riding your ATV in water, be sure to
drain the trapped water by removing the
check hose at the bottom of the air filter
case, the V-belt cooling duct check hose,
the drive select lever box check hose and
the storage compartment check hose. Also,
remove the V-belt case drain plug to drain
any water that may have accumulated.
Wash the ATV in fresh water if it has been
operated in salt water or muddy conditions.
_
1. Air filter case check hose
7-36
1. V-belt cooling duct check hose (left front side of ATV)
1. Drive select lever box check hose
1. Storage compartment check hose
1. V-belt case drain plug
7-37
RIDING OVER ROUGH TERRAIN
Riding over rough terrain should be done with
caution. Look out for obstacles which could
cause damage to the ATV or could lead to an
upset or accident. Be sure to keep your feet
firmly mounted on the footboards at all times.
Avoid jumping the ATV as loss of control and
damage to the ATV may result.
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a colli-
sion. Could cause the ATV to overturn.
Before operating in a new area, check
for obstacles.
Never attempt to ride over large obsta-
cles, such as large rocks or fallen trees.
When you go over obstacles, always fol-
low proper procedures as described in
the Owners Manual.
7-38
SLIDING AND SKIDDING
Care should be used when riding on loose or
slippery surfaces since the ATV may slide. If
unexpected and uncorrected, sliding could
lead to an accident.
To reduce the tendency for the front wheels to
slide in loose or slippery conditions, position-
ing your weight over the front wheels will
sometimes help.
If the rear wheels of your ATV start to slide
sideways, control can usually be regained (if
there is room to do so) by steering in the direc-
tion of the slide. Applying the brakes or accel-
erating is not recommended until you have
corrected the slide.
7-39
With practice, over a period of time, skill at
controlled sliding can be developed. The ter-
rain should be chosen carefully before at-
tempting such maneuvers, since both stability
and control are reduced. Bear in mind that
sliding maneuvers should always be avoided
on extremely slippery surfaces such as ice,
since all control may be lost.
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this ATV. You
may also regain traction unexpectedly,
which may cause the ATV to overturn.
Learn to safely control skidding or slid-
ing by practicing at low speeds and on
level, smooth terrain.
On extremely slippery surfaces, such as
ice, go slowly and be very cautious in
order to reduce the chance of skidding
or sliding out of control.
7-40
WHAT TO DO IF ...
This section is designed to be a reference
guide only. Be sure to read each section on
riding techniques completely.
WHAT TO DO ...
G If your ATV doesnt turn when you want it
to:
Bring the ATV to a stop and practice the
turning maneuvers again. Be sure you are
putting your weight on the footboard to the
outside of the turn. Position your weight
over the front wheels for better control.
(See pages 7-227-23.)
G If your ATV begins to tip while turning:
Lean more into the turn to regain balance. If
necessary, gradually let off the throttle and/
or steer to the outside of the turn. (See
pages 7-227-23.)
G If your ATV starts to slide sideways:
Steer in the direction of the slide if you have
the room. Applying the brakes or accelerat-
ing is not recommended until you have cor-
rected the slide. (See pages 7-387-39.)
G If your ATV cant make it up a hill you are
trying to climb:
Turn the ATV around if you still have for-
ward speed. If not, stop, dismount on the
uphill side of the ATV and physically turn
the ATV around. If the ATV starts to slip
backwards DO NOT USE THE REAR
BRAKE - the ATV may tip over on top of
you. Dismount the ATV on the uphill side.
(See pages 7-247-29.)
7-41
G If your ATV is traversing a sloping surface:
Be sure to ride with your weight positioned
towards the uphill side of the ATV to main-
tain proper balance. If the ATV starts to tip,
steer down the hill (if there are no obstacles
in your way) to regain balance. If you dis-
cover that the ATV is going to tip over, dis-
mount on the uphill side. (See pages 7-32
7-33.)
G If your ATV encounters shallow water:
Ride slowly and carefully through slow
moving water, watching for obstacles. Be
sure to let water drain from the ATV and
CHECK YOUR BRAKES FOR PROPER
OPERATION when you come out of the
water. Do not continue to ride your ATV un-
til you have regained adequate braking
ability. (See pages 7-347-36.)
WARNING
_
8-1
EBU00515
1-PERIODIC MAINTENANCE AND
ADJUSTMENT
Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most
important points of machine inspection, ad-
justment and lubrication are explained on the
following pages.
EBU14510
Owners manual and tool kit
You are recommended to put this owners
manual in the vinyl bag and always carry it on
the bottom of the seat as shown. Put the own-
ers tool kit and low-pressure tire gauge under
the seat.
1. Owners manual
2. Owners tool kit
3. Low-pressure tire gauge
WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause
shocks or can start fires.
Turn off the engine when performing
maintenance unless otherwise speci-
fied.
Have a Yamaha dealer perform service if
you are not familiar with machine ser-
vice.
8-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
The service information included in this man-
ual is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor re-
pairs. The tools provided in the Owners tool
kit are sufficient for this purpose, except that a
torque wrench is also necessary to properly
tighten nuts and bolts.
NOTE:
_
If you do not have a torque wrench available
during a service operation requiring one, take
your machine to a Yamaha dealer to check
the torque settings and adjust them as neces-
sary.
_
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modi-
fications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situ-
ations could lead to an accident.
Never modify this ATV through improp-
er installation or use of accessories. All
parts and accessories added to this ve-
hicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed
and used according to instructions. If
you have questions, consult an autho-
rized Yamaha ATV dealer.
8-3
EBU02611
PERIODIC MAINTENANCE/LUBRICATION
NOTE:
_
G For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
G For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How-
ever, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be
followed.
_
ITEM ROUTINE
Whichever
comes first
INITIAL EVERY
month 1 3 6 6 12
km
(mi)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours 20 75 150 150 300
Valves*
Check valve clearance.
Adjust if necessary.
Cooling system
Check coolant leakage.
Repair if necessary.
Replace coolant every 24 months.
Spark plug
Check condition.
Adjust gap and clean.
Replace if necessary.
Air filter element
Clean.
Every 2040 hours
(More often in wet or dusty areas.)
Carburetor*
Check starter (choke).
Adjust engine idling speed.
Crankcase breather
system*
Check breather hose for cracks or damage.
Exhaust system*
Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
Spark arrester Clean.
8-4
Fuel line*
Check fuel hose for cracks or damage.
Engine oil Replace. (Warm engine before draining.)
Engine oil filter cartridge Replace.
Engine oil strainer* Clean.
Final gear oil
Check oil level/oil leakage.
Replace every 12 months.
Front brake*
Check operation/fluid leakage. (See NOTE page 8-5.)
Correct if necessary.
Rear brake*
Check operation/fluid leakage. (See NOTE page 8-5.)
Select lever safety system
cable*
Check operation.
Adjust if necessary.
V-belt*
Check operation.
Check for cracks or damage.
Wheels*
Check balance/damage/runout.
Repair if necessary.
Wheel bearing*
Check bearing assemblies for looseness/damage.
Replace if damaged.
Front and rear
suspension*
Check operation.
Steering system*
Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.
Rear upper and lower
knuckle pivots*
Lubricate with lithium-soap-based grease.
Drive shaft universal joint* Lubricate with lithium-soap-based grease.
Engine mount* Check for cracks or damage.
Front and rear axle boots*
Check operation.
Replace if damaged.
ITEM ROUTINE
Whichever
comes first
INITIAL EVERY
month 1 3 6 6 12
km
(mi)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours 20 75 150 150 300
8-5
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
G Recommended brake fluid: DOT 4
G Brake fluid replacement:
When disassembling the master cylinders or cal-
ipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinders and
calipers, replace the oil seals every two years.
Replace the brake hoses every four years, or if
cracked or damaged.
WARNING
_
Stabilizer bushes* Check for cracks or damage.
Fittings and fasteners*
Check all chassis fittings and fasteners.
Lights and switches*
Check operation.
Adjust headlight beams.
ITEM ROUTINE
Whichever
comes first
INITIAL EVERY
month 1 3 6 6 12
km
(mi)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours 20 75 150 150 300
8-6
EBU00614
Panel removal and installation
The panels illustrated need to be removed to
perform some of the maintenance described
in this chapter.
Refer to this section each time a panel has to
be removed or reinstalled.
1. Panel A 2. Panel B
1. Panel C 2. Panel D
3. Panel E 4. Panel F
8-7
EBU00700
Panel A, D
To remove
1. Remove the seat.
2. Pull outward on the areas shown, and
then pull upward.
8-8
To install
1. Place the panel in its original position.
2. Install the seat.
8-9
EBU01147
Panel B
To remove
Remove the bolt, and then take the panel off.
To install
Place the panel in the original position and in-
stall the bolt.
CAUTION:
_
When installing the panel, be sure not to
pinch the cables or wires.
_
1. Bolt 2. Panel B
EBU15370
Panel C
To remove
1. Remove the top carrier bolts.
1. Carrier bolt ( 4) (top)
2. Remove the carrier bolts under the fend-
ers, and then take the carrier off.
8-10
1. Bolt ( 2) (under fenders)
3. Remove the quick fastener screws, and
then pull the panel upward to remove.
1. Quick fastener screw ( 2) 2. Panel C
To install
1. Place the panel in the original position,
and then install the quick fastener
screws.
2. Place the carrier in the original position,
and then install the carrier bolts under the
fenders.
3. Install the top carrier bolts, and then tight-
en all bolts to the specified torques.
Tightening torque:
Carrier bolt (top):
34 Nm (3.4 mkgf, 25 ftlbf)
Carrier bolt (under fenders):
7 Nm (0.7 mkgf, 5.1 ftlbf)
8-11
EBU01013
Panel E
To remove
Remove the bolts, and then take the panel off.
To install
Place the panel in the original position, and
then install the bolts.
1. Panel E 2. Bolt ( 3)
EBU00638
Panel F
To remove
Pull outward on the areas shown.
1. Panel F
8-12
To install
Place the panel in its original position.
EBU10992
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed
and the oil filter cartridge replaced at the inter-
vals specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Remove panel F. (See page 8-11 for
panel removal and installation proce-
dures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap and wipe
off the dipstick with a clean rag.
8-13
1. Engine oil filler cap
6. Insert the dipstick in the oil filler hole
(without screwing it in), and then remove
it again to check the oil level.
NOTE:
_
The engine oil should be between the mini-
mum and maximum level marks.
_
1. Maximum level mark 2. Minimum level mark
7. If the engine oil is at or below the mini-
mum level mark, add sufficient oil of the
recommended type to raise it to the cor-
rect level.
8. Insert the dipstick into the oil filler hole,
and then tighten the oil filler cap.
9. Install the panel.
8-14
To change the engine oil (with or without
oil filter cartridge replacement)
1. Remove panel F. (See page 8-11 for
dures.)
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Place an oil pan under the engine to col-
lect the used oil, and then remove the en-
gine oil filler cap.
4. Remove the engine oil drain bolt to drain
the oil from the crankcase.
1. Engine oil drain bolt
NOTE:
_
Skip steps 59 if the oil filter cartridge is not
being replaced.
_
5. Remove panels D and E. (See pages
8-78-8, 8-11 for panel removal and in-
stallation procedures.)
6. Remove the oil filter cartridge with an oil
filter wrench.
1. Engine oil filter cartridge
8-15
1. Oil filter wrench
NOTE:
_
An oil filter wrench is available at a nearby
Yamaha dealer.
_
7. Apply a light coat of engine oil to the
O-ring of the new oil filter cartridge.
NOTE:
_
Make sure the O-ring is seated properly.
_
1. O-ring
8. Install the new oil filter cartridge with an
oil filter wrench, and then tighten it to the
specified torque with a torque wrench.
Tightening torque:
Oil filter cartridge:
8-16
1. Torque wrench
9. Install panels E and D.
10. Install the engine oil drain bolt, and then
tighten it to the specified torque.
11. Add the specified amount of recommend-
ed engine oil, and then install the engine
oil filler cap and tighten it.
CAUTION:
_
G In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of CD or oils of a high-
er quality than specified. In addition,
do not use oils labeled ENERGY
CONSERVING II or higher.
G Make sure that no foreign material en-
ters the crankcase.
_
Tightening torque:
Engine oil drain bolt:
Recommended engine oil:
See page 10-2.
Oil quantity:
Without oil filter cartridge replacement:
2.30 L (2.02 Imp qt, 2.43 US qt)
With oil filter cartridge replacement:
2.40 L (2.11 Imp qt, 2.54 US qt)
8-17
12. Start the engine and warm it up for seve-
ral minutes. While warming up, check for
oil leakage. If oil leakage is found, turn
the engine off immediately and check for
the cause.
13. Turn the engine off, and then check the
oil level and correct it if necessary.
14. Install panel F.
EBU15380
Final gear oil
Checking the final gear oil level
2. Remove the oil filler bolt, and then check
the oil level in the final gear case.
NOTE:
_
The oil level should be at the brim of the filler
hole.
_
3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended
type to raise it to the correct level.
1. Final gear oil drain bolt 2. Correct level
3. Final gear oil
8-18
CAUTION:
_
Be sure no foreign material enters the final
gear case.
_
4. Install the oil filler bolt, and then tighten it
to the specified torque.
Changing the final gear oil
1. Remove the engine guard and the final
gear case guard by removing the bolts.
1. Engine guard 2. Final gear case guard
3. Bolt ( 11)
3. Place a container under the final gear
case to collect the used oil.
Tightening torque:
Final gear oil filler bolt:
8-19
4. Remove the oil filler bolt and the drain
bolt to drain the oil.
1. Final gear oil drain bolt
5. Install the drain bolt, and then tighten it to
the specified torque.
6. Add the recommended final gear oil to
the brim of the filler hole.
CAUTION:
_
Be sure no foreign material enters the final
gear case.
_
7. Install the oil filler bolt, and then tighten it
to the specified torque.
8. Check for oil leakage. If oil leakage is
found, check for the cause.
Tightening torque:
Final gear oil drain bolt:
Recommended oil:
Oil quantity:
0.23 L (0.20 Imp qt, 0.24 US qt)
Tightening torque:
Final gear oil filler bolt:
8-20
9. Install the engine guard and the final gear
case guard by installing the bolts, and
then tightening them to the specified
torques.
EBU07063
Checking the differential gear oil
2. Remove the differential gear oil filler bolt
and check the oil level. It should be up to
the brim of the filler hole. If the level is
low, add sufficient oil of the recommend-
ed type to raise it to the specified level.
1. Differential gear oil
2. Differential gear oil filler bolt
3. Specified level
Tightening torques:
Engine guard bolt:
7.0 Nm (0.7 mkgf, 5.1 ftlbf)
Final gear case guard bolt:
7.0 Nm (0.7 mkgf, 5.1 ftlbf)
8-21
CAUTION:
_
Be sure no foreign material enters the dif-
ferential gear case.
_
3. Install the differential gear oil filler bolt,
and then tighten it to the specified torque.
Replacing the differential gear oil
2. Place a container under the differential
gear case to collect the used oil.
3. Remove the differential gear oil filler bolt
and differential gear oil drain bolt to drain
the oil.
1. Differential gear oil drain bolt
4. Install the differential gear oil drain bolt
and tighten it to the specified torque.
5. Fill the differential gear case with the rec-
ommended oil.
Tightening torque:
Differential gear oil filler bolt:
Tightening torque:
Differential gear oil drain bolt:
8-22
CAUTION:
_
Be sure no foreign material enters the dif-
ferential gear case.
_
6. Install the differential gear oil filler bolt,
7. Check for oil leakage. If oil leakage is
found, check for the cause.
EBU12560
Cooling system
2. Check the coolant level in the coolant
reservoir when the engine is cold as the
coolant level will vary with engine tem-
perature.
NOTE:
_
The coolant should be between the minimum
and maximum level marks.
_
1. Coolant reservoir cap
2. Maximum level mark 3. Minimum level mark
Recommended oil:
Oil quantity:
0.23 L (0.20 Imp qt, 0.24 US qt)
Tightening torque:
Differential gear oil filler bolt:
8-23
3. If the coolant is at or below the minimum
level mark, remove panel D (See pages
8-78-8, 8-11 for panel removal and in-
stallation procedures.), remove the reser-
voir cap, add coolant to the maximum
level mark, install the reservoir cap, and
then install the panel.
CAUTION:
_
_
NOTE:
_
G If water is added, have a Yamaha dealer
check the antifreeze content of the cool-
ant as soon as possible.
G The radiator fan operation is completely
automatic. It is switched on or off accord-
ing to the coolant temperature in the radi-
ator.
_
If your ATV overheats, see page 8-62 for de-
tails.
0.25 L (0.22 Imp qt, 0.26 US qt)
8-24
EBU12572
Changing the coolant 1. Place the ATV on a level surface.
2. Remove panels E and F. (See pages
8-118-12 for panel removal and installa-
tion procedures.)
3. Place a container under the engine, and
then remove the coolant drain bolt. (Use
a trough or a similar object as shown to
prevent coolant from spilling on the foot-
rest.)
1. Coolant drain bolt
WARNING
POTENTIAL HAZARD
WHAT CAN HAPPEN
moving the radiator cap. Always use a
thick rag over the cap. Allow any re-
maining pressure to escape before
completely removing the cap.
8-25
1. Trough
4. Remove the front carrier and panel C.
(See pages 8-98-10 for removal and in-
5. Remove the radiator cap.
1. Radiator cap
6. Remove panel D. (See pages 8-78-8 for
dures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant res-
ervoir side, and then drain the coolant
from the coolant reservoir.
8-26
1. Coolant reservoir hose
9. After draining the coolant, thoroughly
flush the cooling system with clean tap
water.
10. Replace the coolant drain bolt washer if it
is damaged, install the coolant drain bolt,
11. Install the coolant reservoir hose.
12. Pour the recommended coolant into the
reservoir to the maximum level mark, and
then install the reservoir cap and panel D.
13. Pour the recommended coolant into the
radiator until it is full, and then install the
radiator cap.
Tightening torque:
Coolant drain bolt:
Recommended antifreeze:
High quality ethylene glycol antifreeze
containing corrosion inhibitors for
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.30 L (1.14 Imp qt, 1.37 US qt)
0.25 L (0.22 Imp qt, 0.26 US qt)
8-27
CAUTION:
_
_
14. Start the engine and let it idle for several
minutes. Stop the engine, and then
check the coolant level in the radiator. If it
is low, add more coolant until it reaches
the top of the radiator.
15. Check for coolant leakage.
NOTE:
_
If any leakage is found, have a Yamaha deal-
er check the cooling system.
_
16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears.
If any damage is found, have them replaced
by a Yamaha dealer.
1. Front axle boot ( 2 each side)
8-28
1. Rear axle boot ( 2 each side)
EBU00864
Spark plug inspection
Removal
1. Remove panel A. (See pages 8-78-8 for
dures.)
2. Remove the spark plug cap.
1. Spark plug cap
8-29
3. Use the spark plug wrench in the tool kit
to remove the spark plug as shown.
1. Spark plug wrench
Inspection
The spark plug is an important engine compo-
nent and is easy to inspect. The condition of
the spark plug can indicate the condition of
the engine.
The ideal color on the white insulator around
the center electrode is a medium-to-light tan
color for a ATV that is being ridden normally.
Do not attempt to diagnose such problems
yourself.
Instead, take the ATV to a Yamaha dealer.
You should periodically remove and inspect
the spark plug because heat and deposits will
cause the spark plug to slowly break down
and erode. If electrode erosion becomes ex-
cessive, or if carbon and other deposits are
excessive, you should replace the spark plug
with the specified plug.
Installation
1. Measure the electrode gap with a wire
thickness gauge and, if necessary, adjust
the gap to specification.
Specified spark plug:
DR8EA (NGK)
Spark plug gap:
0.60.7 mm (0.0240.028 in)
8-30
a. Spark plug gap
2. Clean the gasket surface. Wipe off any
grime from the threads.
3. Install the spark plug and tighten it to the
specified torque.
NOTE:
_
If a torque wrench is not available when you
are installing a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 turn past finger
tight. Have the spark plug tightened to the
specified torque as soon as possible.
_
4. Install the spark plug cap.
Tightening torque:
Spark plug:
17.5 Nm (1.75 mkgf, 12.5 ftlbf)
8-31
EBU15140
Air filter element cleaning
NOTE:
_
There is a check hose at the bottom of the air
filter case. If dust or water collects in this
hose, empty the hose and clean the air filter
element and air filter case.
_
1. Air filter case check hose
1. Remove the seat. (See pages 4-204-21
for seat removal and installation proce-
dures.)
2. Remove the air filter case cover by un-
hooking the fasteners.
1. Fastener ( 4) 2. Air filter case cover
3. Remove the air filter element assembly.
1. Air filter element assembly
8-32
4. Pull off the lock plate, and then remove
the air filter element from its frame.
1. Air filter element frame 2. Air filter element
3. Lock plate
5. Wash the element gently but thoroughly
in solvent.
6. Squeeze the excess solvent out of the air
filter element and let it dry.
CAUTION:
_
Do not twist the air filter element when
squeezing it.
_
7. Inspect the air filter element and replace
it if damaged.
WARNING
POTENTIAL HAZARD
Using low flash point solvents or gaso-
line to clean the air filter element.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can
catch fire or explode.
Use parts cleaning solvent to clean the
air filter element.
8-33
8. Apply Yamaha foam air filter oil or other
quality foam air filter oil to the air filter el-
ement.
NOTE:
_
The air filter element should be wet but not
dripping.
_
9. Pull the air filter element over its frame,
and then install the lock plate.
10. Install the air filter element assembly.
11. Install the air filter case cover by hooking
the fasteners onto the air filter case.
12. Install the seat.
NOTE:
_
The air filter element should be cleaned every
2040 hours. It should be cleaned and lubri-
cated more often if the machine is operated in
extremely dusty areas. Each time the air filter
element maintenance is performed, check the
air inlet to the filter case for obstructions.
Check the air filter case rubber joint to the car-
buretor and manifold fittings for an airtight
seal. Tighten all fittings securely to avoid the
possibility of unfiltered air entering the engine.
_
CAUTION:
_
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, op-
eration without the air filter element will af-
fect carburetor jetting with subsequent
poor performance and possible engine
overheating.
_
8-34
EBU06411
V-belt cooling duct check hose
If dust or water collects in the V-belt cooling
duct check hose, remove the hose and clean
it.
1. V-belt cooling duct check hose (left front side of ATV)
EBU08741
V-belt case drain plug
After riding in water deep enough to allow it to
enter the V-belt case, remove this plug to
drain the water from the case.
NOTE:
_
If water drains from the V-belt case after re-
moving the plug, have a Yamaha dealer in-
spect the ATV as the water may affect other
engine parts.
_
1. V-belt case drain plug
8-35
EBU01066
Spark arrester cleaning
Be sure the exhaust pipe and muffler are cool
before cleaning the spark arrester.
1. Remove the bolts.
2. Remove the tailpipe by pulling it out of
the muffler.
1. Bolt ( 3) 2. Tailpipe
3. Tap the tailpipe lightly, and then use a
wire brush to remove any carbon depos-
its from the spark arrester portion of the
tailpipe.
1. Tailpipe 2. Spark arrester
4. Insert the tailpipe into the muffler and
align the bolt holes.
5. Install and tighten the bolts.
8-36
EBU00296
Carburetor adjustment
The carburetor is a vital part of the engine and
requires very sophisticated adjustment. Most
adjusting should be left to a Yamaha dealer
who has the professional knowledge and ex-
perience to do so. However, the idling speed
may be performed by the owner as a part of
the usual maintenance routine.
CAUTION:
The carburetor was set at the Yamaha fac-
tory after many tests. If the settings are
disturbed by someone without sufficient
technical knowledge, poor engine perfor-
mance and damage may result.
WARNING
POTENTIAL HAZARD
Improper cleaning of the spark arrester.
Hot exhaust system
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poison-
ing, possibly leading to death.
Could start a fire.
When cleaning the spark arrester:
Always let the exhaust system cool pri-
or to touching exhaust components.
Do not start the engine when cleaning
the exhaust system.
8-37
EBU12580
Idle speed adjustment
NOTE:
_
A diagnostic tachometer must be used for this
procedure.
_
1. Start the engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the engine
to 4,000 to 5,000 r/min. The engine is
warm when it quickly responds to the
throttle.
2. Remove panel D. (See pages 8-78-8 for
removal and installation procedures.)
3. Connect the tachometer to the spark plug
lead, and then set the idle to the specified
idling speed by adjusting the throttle stop
screw. Turn the screw in direction a to
increase the engine speed, and in direc-
tion b to decrease the engine speed.
1. Throttle stop screw
Specified idle speed:
1,4501,550 r/min
8-38
EBU00303
Valve clearance adjustment
The correct valve clearance changes with
use, resulting in improper fuel/air supply or
engine noise. To prevent this, the valve clear-
ance must be adjusted regularly. This adjust-
ment however, should be left to a professional
Yamaha service technician.
EBU00307
Throttle lever adjustment
NOTE:
Adjust the engine idling speed before adjust-
ing the throttle lever free play.
1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle le-
ver free play is 3.05.0 mm (0.12
0.20 in).
3. Tighten the locknut.
1. Locknut 2. Adjusting bolt
a. Throttle lever free play
8-39
EBU03050
Select lever safety system cable
adjustment
The select lever safety system cable stretch-
es with use, resulting in improper function. To
prevent this, the cable must be adjusted regu-
larly. This adjustment, however, should be left
to a Yamaha dealer.
EBU13090
Front brake pad check
Check the brake pads for damage and wear.
If a brake pad thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the
pads as a set.
a. Brake pad thickness
NOTE:
_
The wheels need to be removed to check the
brake pads. (See pages 8-498-50 for remov-
al and installation procedures.)
_
8-40
EBU06212
Rear brake pad check
Check the brake pads for damage or wear.
Wear indicator grooves are provided on the
brake pads. These indicators allow checking
of brake pad wear without disassembling the
brake. Check the wear indicator grooves. If a
brake pad has worn to the point that the wear
indicator grooves have almost disappeared,
ask a Yamaha dealer to replace the pads as a
set.
1. Brake pad wear indicator groove
NOTE:
_
The wheels need to be removed to check the
brake pads. (See pages 8-498-50 for wheel
removal and installation procedures.)
_
8-41
EBU06221
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the
brake system, possibly causing the brakes to
become ineffective.
Before riding, check that the brake fluid is
above the minimum level mark and replenish
when necessary. A low brake fluid level may
indicate worn brake pads and/or brake sys-
tem leakage. If the brake fluid level is low, be
sure to check the brake pads for wear and the
brake system for leakage. The rear brake fluid
master cylinder reservoir is located under
panel C. (See pages 8-98-10 for panel re-
moval and installation procedures.)
1. Minimum level mark
1. Minimum level mark
FRONT
REAR
8-42
Observe these precautions:
G When checking the fluid level, make sure
the top of the master cylinder reservoirs are
level.
G Use only the designated quality brake fluid.
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
G Refill with the same type of brake fluid. Mix-
ing fluids may result in a harmful chemical
reaction and lead to poor brake perfor-
mance.
G Be careful that water does not enter the
master cylinder reservoirs when refilling.
Water will significantly lower the boiling
point of the fluid and may result in vapor
lock.
G Brake fluid may deteriorate painted surfac-
es or plastic parts. Always clean up spilled
fluid immediately.
G Have a Yamaha dealer check the cause if
the brake fluid level goes down.
EBU11860
Brake fluid replacement
Complete fluid replacement should be done
only by trained Yamaha service personnel.
Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.
G Replace the oil seals every two years.
G Replace the brake hoses every four years.
Recommended brake fluid: DOT 4
8-43
EBU11870
Front brake lever free play
The front brake lever should have a free play
of zero mm (zero in) at the lever end. If not,
have a Yamaha dealer check the brake sys-
tem.
a. Front brake lever free play
WARNING
POTENTIAL HAZARD
Operating with improperly serviced or
adjusted brakes.
WHAT CAN HAPPEN
After servicing:
G Make sure the brakes operate
smoothly and that the free play is
correct.
G Make sure the brakes do not drag.
G Make sure the brakes are not
spongy. All air must be bled from
the brake system.
Replacement of brake components re-
quires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
8-44
EBU09631
Adjusting the rear brake lever and brake
pedal
Adjusting the rear brake lever
The rear brake lever free play should be 0.5
2.0 mm (0.020.08 in).
1. Loosen the locknut.
1. Locknut 2. Adjusting bolt
c. Rear brake lever free play
2. Turn the adjusting bolt in direction a to
increase free play, and in direction b to
decrease free play.
3. Tighten the locknut.
If correct free play cannot be obtained, ask a
Yamaha dealer to make that adjustment.
NOTE:
_
When adjusting the rear brake lever free play:
G Be sure not to step on the brake pedal.
G Make sure the brake pedal does not
move.
_
8-45
Adjusting the brake pedal
The top of the brake pedal should be posi-
tioned 72 mm (2.83 in) above the top of the
footrest. If not, ask a Yamaha dealer to adjust
it.
a. Brake pedal position
WARNING
POTENTIAL HAZARD
Operating with improperly serviced or
adjusted brakes.
WHAT CAN HAPPEN
After servicing:
G Make sure the brakes operate
smoothly and that the free play is cor-
rect.
G Make sure the brakes do not drag.
G All air must be bled from the brake
system.
Replacement of brake components re-
quires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
8-46
EBU12590
Adjusting the rear brake light switch
The rear brake light switch, which is activated
by the brake pedal and rear brake lever, is
properly adjusted when the brake light comes
on just before braking takes effect. If neces-
sary, adjust the brake light switch as follows.
1. Remove panel B. (See page 8-9 for pan-
el removal and installation procedures.)
2. Turn the adjusting nut while holding the
rear brake light switch in place. To make
the brake light come on earlier, turn the
adjusting nut in direction a. To make the
brake light come on later, turn the adjust-
ing nut in direction b.
1. Rear brake light switch 2. Adjusting nut
8-47
EBU00356
Cable inspection and lubrication
Lubricate the inner cables and the cable ends.
If the cables do not operate smoothly, ask a
Yamaha dealer to replace them.
EBU12600
Lubricating the brake levers and brake
pedal
Lubricate the pivoting parts.
NOTE:
_
To access the brake pedal pivot, remove pan-
el B. (See page 8-9 for panel removal and in-
_
WARNING
POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion can result when the outer
covering of control cables becomes
damaged. Cables can also become
frayed or kinked. Operation of controls
could be restricted, which could cause
an accident or injury.
Inspect cables frequently. Replace dam-
aged cables.
Recommended lubricant:
Yamaha chain and cable lube or
SAE 10W30 motor oil
Lithium-soap-based grease
(all-purpose grease)
8-48
EBU13110
Rear knuckle upper and lower pivot
lubrication
Lubricate the knuckle upper and lower pivots
with a grease gun.
1. Upper knuckle 2. Lower knuckle
Lithium-soap-based grease
8-49
EBU01112
Wheel removal
1. Loosen the wheel nuts.
2. Elevate the ATV and place a suitable
stand under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
1. Nut ( 4)
EBU11211
Wheel installation
1. Install the wheel and the nuts.
NOTE:
_
G The arrow mark on the tire must point
toward the rotating direction of the wheel.
G Tapered nuts are used for both the front
and rear wheels. Install the nut with its ta-
pered side towards the wheel.
_
1. Arrow mark
8-50
2. Lower the ATV so that the wheel is on the
ground.
1. Tapered nut
3. Tighten the wheel nuts to the specified
torque.
EBU00380
Battery
This machine is equipped with a sealed-type
battery. Therefore it is not necessary to check
the electrolyte or add distilled water in the bat-
tery. If the battery seems to have discharged,
consult a Yamaha dealer.
1. Negative battery terminal 2. Positive battery terminal
Wheel nut torque:
Front: 55 Nm (5.5 mkgf, 40 ftlbf)
Rear: 55 Nm (5.5 mkgf, 40 ftlbf)
8-51
CAUTION:
Do not try to remove the sealing caps of
the battery cells. You may damage the bat-
tery.
WARNING
POTENTIAL HAZARD
Failure to handle batteries or battery
electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be
severely burned by the sulfuric acid in
battery electrolyte. Batteries produce
explosive gases.
Avoid contact with skin, eyes or cloth-
ing. Always shield eyes when working
near batteries. Keep out of reach of chil-
dren.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of wa-
ter or milk. Follow with milk of magne-
sia, beaten egg or vegetable oil. Get
prompt medical attention.
EYES: Flush with water for 15 minutes
and get prompt medical attention. Keep
batteries away from sparks, flames, cig-
arettes or other sources of ignition. Ven-
tilate when charging or using in a closed
space.
8-52
EBU00385
Battery maintenance
1. When the machine is not used for a
month or longer, remove the battery and
store it in a cool, dark place. Completely
recharge the battery before reinstallation.
CAUTION:
A special battery charger (constant volt-
age/ampere or constant voltage) is re-
quired for recharging a sealed-type
battery. Using a conventional battery
charger may shorten the battery life.
2. Always make sure the connections are
correct when putting the battery back in
the machine.
EBU08762*
Fuse replacement
1. The main fuse and the fuse box are locat-
ed under the seat.
2. If a fuse is blown, turn off the main switch
and the switch of the circuit in question.
Then, install a new fuse of the specified
amperage. Turn on the main switch. If
the fuse immediately blows again, con-
sult a Yamaha dealer.
8-53
1. Main fuse 2. Fuse box
1. Main fuse 2. Spare main fuse
1. Headlight fuse 2. Ignition fuse
3. Auxiliary DC jack fuse 4. Four-wheel drive fuse
5. Signaling system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse ( 3)
Specified fuses:
Main fuse: 30.0 A
Headlight fuse: 15.0 A
Ignition fuse: 10.0 A
Auxiliary DC jack fuse: 10.0 A
Four-wheel drive fuse: 3.0 A
Signaling system fuse: 10.0 A
Backup fuse: 10.0 A
8-54
CAUTION:
_
To prevent accidental short-circuiting,
turn off the main switch when checking or
replacing a fuse.
_
EBU14560
Replacing a headlight bulb
If a headlight bulb burns out, replace it as fol-
lows.
1. Remove the bulb holder cover at the rear
of the headlight by pulling it off.
1. Headlight bulb holder cover
WARNING
POTENTIAL HAZARD
Using an improper fuse.
WHAT CAN HAPPEN
An improper fuse can cause damage to
the electrical system which could lead
to a fire.
Always use a fuse of the specified rat-
ing. Never use a material in place of the
proper fuse.
8-55
2. Remove the headlight bulb holder by
turning it counterclockwise.
1. Headlight bulb holder
3. Remove the defective bulb by unhooking
the headlight bulb holder tabs.
1. Headlight bulb holder tab ( 2)
8-56
4. Insert a new headlight bulb into the bulb
holder, and then secure the bulb by
hooking the tabs onto the bulb.
1. Do not touch the glass part of the bulb.
CAUTION:
_
Do not touch the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the luminos-
ity of the bulb, and the bulb life will be ad-
versely affected. Thoroughly clean off any
dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or
thinner.
_
WARNING
POTENTIAL HAZARD
A headlight bulb is hot when it is on and
immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start
if the bulb touches something flamma-
ble.
Wait for the bulb to cool before touching
or removing it.
8-57
5. Install the headlight bulb holder by turn-
ing it clockwise.
6. Install the headlight bulb holder cover at
the rear of the headlight.
EBU01089
Headlight beam adjustment
CAUTION:
_
It is advisable to have a Yamaha dealer
make this adjustment.
_
To raise the beam, turn the adjusting screw in
direction a.
To lower the beam, turn the adjusting screw in
direction b.
1. Headlight beam adjusting screw
8-58
EBU09640
Tail/brake light bulb replacement
1. Remove the nuts together with the wash-
ers.
1. Tail/brake light unit 2. Nut ( 2)
2. Remove the bulb holder (together with
the bulb) by turning it counterclockwise.
1. Tail/brake light unit 2. Tail/brake light bulb holder
3. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
8-59
1. Tail/brake light bulb holder 2. Bulb
4. Install a new bulb in the bulb holder by
pushing it inward and turning it clockwise.
5. Install the bulb holder (together with the
bulb) by turning it clockwise.
6. Install the washers, and then install the
nuts.
EBU00412
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory,
trouble may occur during operation. Any prob-
lem in the fuel, compression, or ignition sys-
tems can cause poor starting and loss of
power. The troubleshooting chart describes a
quick, easy procedure for making checks. If
your machine requires any repair, take it to a
Yamaha dealer.
The skilled technicians at a Yamaha dealer-
ship have the tools, experience, and know-
how to properly service your machine. Use
only genuine Yamaha parts on your machine.
Imitation parts may look like Yamaha parts,
but they are often inferior. Consequently, they
have a shorter service life and can lead to ex-
pensive repair bills.
8-60
WARNING
POTENTIAL HAZARD
Checking the fuel system while smok-
ing or near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing se-
vere injury or property damage.
Do not smoke when checking the fuel
system. Make sure there are no open
flames or sparks in the area, including
pilot lights from water heaters or furnac-
es.
8-61
EBU08061
Troubleshooting charts
Starting problems or poor engine performance
1. Fuel
Check if there is fuel
in the fuel tank.
There is fuel.
Turn the fuel cock
lever to OFF.
No fuel.
Fuel cock is
clogged.
Clean the
fuel cock.
Some fuel.
Turn the fuel cock
lever to RES.
Restart the engine.
No fuel.
Supply fuel.
2. Compression
Use the electric
starter to see if
there is compression.
There is compression. Compression normal.
No compression.
Ask a Yamaha dealer to
inspect.
3. Ignition
Remove the
spark plug and
check the electrodes.
Wet Wipe clean with dry cloth.
Dry
Attach spark plug cap and
ground to chassis.
Use the
electric starter.
Spark is good.
Ignition system is
normal.
Spark is weak.
Adjust the spark plug gap
or replace the spark plug.
No spark.
Ask a Yamaha dealer to
inspect.
4. Battery
Use the electric starter.
Engine turns over
quickly.
Battery is good.
Engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Check the
fuel flow.
Turn the fuel cock
lever to ON.
Remove the fuel hose
from the fuel cock.
8-62
Engine overheating
NOTE:
_
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that
it is changed to the recommended coolant as soon as possible.
_
WARNING
POTENTIAL HAZARD
WHAT CAN HAPPEN
moving the radiator cap.
Always use a thick rag over the cap. Al-
low any remaining pressure to escape
before completely removing the cap.
Wait until the
engine has cooled.
Check the coolant level in the
coolant reservoir and/or radiator.
Level is OK.
Level is low, check the
cooling system for leakage.
No
leakage.
Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.
Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
9-1
EBU00419
1-CLEANING AND STORAGE
A. CLEANING
Frequent, thorough cleaning of your machine
will not only enhance its appearance but will
improve its general performance and extend
the useful life of many components.
1. Before cleaning the machine:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler
caps are properly installed.
2. If the engine case is excessively greasy,
apply degreaser with a paint brush. Do
not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose. Use only enough pressure
to do the job.
CAUTION:
Excessive water pressure may cause wa-
ter seepage and deterioration of wheel
bearings, brakes, transmission seals and
electrical devices. Many expensive repair
bills have resulted from improper high
pressure detergent applications such as
those available in coin-operated car wash-
ers.
4. Once the majority of the dirt has been
hosed off, wash all surfaces with warm
water and mild, detergent-type soap. An
old toothbrush or bottle brush is handy for
hard-to-get-at places.
5. Rinse the machine off immediately with
clean water and dry all surfaces with a
chamois, clean towel or soft absorbent
cloth.
9-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
6. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
7. Automotive type wax may be applied to
all painted and chrome plated surfaces.
Avoid combination cleaner-waxes. Many
contain abrasives which may mar the
paint or protective finish. When finished,
start the engine and let it idle for several
minutes.
WARNING
POTENTIAL HAZARD
Operation with wet brakes after wash-
ing.
WHAT CAN HAPPEN
Wet brakes may have reduced stopping
ability, increasing the chance of an acci-
dent.
Test the brakes after washing. Apply the
brakes several times at slow speeds to
let friction dry out the linings.
9-3
EBU00530
B. STORAGE
Long term storage (60 days or more) of your
machine will require some preventive proce-
dures to guard against deterioration. After
thoroughly cleaning the machine, prepare for
storage as follows:
1. Fill the fuel tank with fresh fuel and add
the specified amount of Yamaha Fuel
Stabilizer and Conditioner or an equiva-
lent product.
NOTE:
Use of fuel stabilizer and conditioner elimi-
nates the need to drain the fuel system. Con-
sult a Yamaha dealer if the fuel system needs
to be drained instead.
2. Remove the spark plug, pour about one
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and rein-
stall the spark plug. Ground the spark
plug wire and turn the engine over seve-
ral times to coat the cylinder wall with oil.
3. Lubricate all control cables.
4. Block up the frame to raise all wheels off
the ground.
5. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
6. If storing in a humid or salt-air atmo-
sphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil to
any rubber parts or the seat cover.
Specified amount:
1 oz of stabilizer to each gallon of fuel
(or 7.5 cc of stabilizer to each liter of
fuel)
9-4
7. Remove the battery and charge it. Store
it in a dry place and recharge it once a
month. Do not store the battery in an ex-
cessively warm or cold place (less than
0 C (30 F) or more than 30 C (90 F)).
NOTE:
Make any necessary repairs before storing
the machine.
10-1
EBU00428
1-SPECIFICATIONS
Model
YFM450FA
Dimensions:
Overall length 1,993 mm (78.5 in)
Overall width 1,093 mm (43.0 in)
Overall height 1,120 mm (44.1 in)
Seat height 830 mm (32.7 in)
Wheelbase 1,233 mm (48.5 in)
Ground clearance 245 mm (9.65 in)
Minimum turning radius 3,000 mm (118.1 in)
Basic weight:
With oil and full fuel tank 285.0 kg (628 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 421.0 cm
3
Bore stroke 84.5 75.0 mm (3.33 2.95 in)
Compression ratio 10.00 : 1
Starting system Electric and recoil starter
Lubrication system Wet sump
10-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Engine oil:
Type
Recommended engine oil classification API Service SE, SF, SG type or higher
Quantity:
Without oil filter cartridge replacement 2.30 L (2.02 Imp qt, 2.43 US qt)
With oil filter cartridge replacement 2.40 L (2.11 Imp qt, 2.54 US qt)
Model
YFM450FA
0 10 30 50 70 90 110 130F
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
-20 -10 0 10 20 30 40 50C
YAMALUBE 4 (20W40) or SAE 20W40
CAUTION:
In order to prevent clutch slippage (since the en-
gine oil also lubricates the clutch), do not mix any
chemical additives. Do not use oils with a diesel
specification of CD or oils of a higher quality
than specified. In addition, do not use oils labeled
ENERGY CONSERVING II or higher.
10-3
Final gear case oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L (0.20 Imp qt, 0.24 US qt)
Differential gear case oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L (0.20 Imp qt, 0.24 US qt)
Radiator capacity (including all routes): 1.30 L (1.14 Imp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type UNLEADED GASOLINE ONLY
Fuel tank capacity 15.0 L (3.30 lmp gal, 3.96 US gal)
Fuel reserve amount 4.5 L (0.99 lmp gal, 1.19 US gal)
Carburetor:
Type/quantity BSR33 / 1
Manufacturer MIKUNI
Model
YFM450FA
10-4
Spark plug:
Type/manufacturer DR8EA / NGK
Spark plug gap 0.60.7 mm (0.0240.028 in)
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 39/24 24/18 33/9 (7.944)
Transmission type V-belt automatic
Operation Left hand operation
Reverse gear 29/17 (1.706)
Sub transmission ratio low 45/16 (2.813)
high 38/23 (1.652)
Chassis:
Frame type Steel tube frame
Caster angle 2.5
Trail 8.5 mm (0.33 in)
Tire:
Type Tubeless
Size front AT25 8 - 12
rear AT25 10 - 12
Model
YFM450FA
10-5
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Left hand and right foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Double wishbone
Shock absorber:
Front shock absorber Coil spring / oil damper
Rear shock absorber Coil spring / oil damper
Wheel travel:
Front wheel travel 160.0 mm (6.30 in)
Rear wheel travel 180.0 mm (7.09 in)
Electrical:
Ignition system DC. C.D.I.
Generator system A.C. magneto
Battery type YTX20L-BS
Battery capacity 12 V 18.0 Ah
Headlight type: Krypton bulb
Model
YFM450FA
10-6
Bulb voltage, wattage quantity:
Headlight 12 V 30W/30.0 W 2
Tail/brake light 12 V 5W/21.0 W 1
Indicator light:
Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Park indicator light LED
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
Fuses:
Main fuse 30.0 A
Headlight fuse 15.0 A
Ignition fuse 10.0 A
Auxiliary DC jack fuse 10.0 A
Four-wheel drive fuse 3.0 A
Signaling system fuse 10.0 A
Backup fuse 10.0 A
Model
YFM450FA
11-1
EBU00430
1- NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-
erative by any person other than for purposes of maintenance, repair, or replacement of any de-
vice or element of design incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after
such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust
system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
12-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EBU13653
1- MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to docu-
ment maintenance done in accordance with the warranty. The chart below is printed only as a re-
minder to you that the maintenance work is required. It is not acceptable proof of maintenance
work.
ACL-06E
MAINTENANCE
INTERVAL
DATE OF
SERVICE
MILEAGE
SERVICING DEALER
NAME AND ADDRESS
REMARKS
month km (mi) hours
1 320 (200) 20
3 1,200 (750) 75
6 2,400 (1,500) 150
12 4,800 (3,000) 300
18 7,200 (4,500) 450
24 9,600 (6,000) 600
30 12,000 (7,500) 750
36 14,400 (9,000) 900
42 16,800 (10,500) 1,050
48 19,200 (12,000) 1,200
54 21,600 (13,500) 1,350
60 24,000 (15,000) 1,500
13-1
EBU00432
YAMAHA MOTOR CORPORATION, U.S.A.
ATV LIMITED WARRANTY
13-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
14-1
EBU00435
YAMAHA EXTENDED SERVICE (Y.E.S.)
14-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EBU00436
WARNING
_
EBU00437
1D9-F8199-10 LIT-11626-18-35
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM450FAT
OWNERS MANUAL
PRINTED IN USA
2004.06-4.41 CR
(E)
YAMAHA MOTOR CO., LTD.
EBU00438
LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
WARNING
ALWAYS:
use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
avoid paved surfaces-pavement may
seriously affect handling and control.
Improper ATV use can result in SEVERE INJURY or DEATH.
NEVER operate:
without proper training or instruction.
at speeds too fast for your skills or the
conditions.
on public roads-a collision can occur with
another vehicle.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
B
E E R
B
E E R

Yamaha Kodiak 450 Lit-11626-18-35 - 972

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Yamaha Kodiak 450 Lit-11626-18-35 - 972

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1D9-F8199-10 LIT-11626-18-35

READ THIS MANUAL CAREFULLY!

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